Method of detecting, diagnosing and automatically correcting abnormalities in servo control system

ABSTRACT

According to the present invention, in a first acceleration after power is turned ON, currents flowing through U-phase and V-phase of a servo motor output terminal are detected, and misconnection of the motor output terminal is detected by monitoring a pattern of the current wave form.

This is a divisional of application Ser. No. 09/123,556 filed Jul. 29,1998, which is a divisional of application Ser. No. 08/588,396 , filedJan 18, 1996 now U.S. Pat. No. 5,825,150, the disclosures of which areincorporated herein by reference.

FIELD OF THE INVENTION

The present invention relates to a method of detecting and diagnosing aswell as a method for correcting abnormalities in a servo control systemused in, for instance, a numerical control system controlling amachining tool, a robot or the like.

BACKGROUND OF THE INVENTION

FIG. 43 shows a general servo motor driver used in a servo controlsystem. The servo motor driver comprises a rectifying circuit 2 forrectifying a 3-phase alternating current given from a 3-phasealternating current source 1, a smoothing capacitor 3 for smoothing arectified output from the rectifying circuit 2, a semiconductorswitching circuit 4 receiving an DC current smoothed by the smoothingcapacitor 3 as an input and constituting an output section of a PWMcircuit outputting the 3-phase AC current having been subjected to PWMconversion to an AC servo motor 8, a current detecting section 5 fordetecting from a chant resistor CT values of U-phase and V-phasecurrents each flowing into the AC servo motor 8 from the semiconductorswitching circuit 4, an A/D converter 6 for converting an analog voltagesignal proportional to a current value detected by the current detectingsection 5 to a digital signal, and a CPU 7 fetching a digital signaloutputted from the A/D converter 6 as a current feedback signal,executing a specified computing operation according to a currentfeedback value and a speed command value, and outputting a PWM signalfor each phase to a base terminal for each phase in the semiconductorswitching circuit 4.

It should be noted that, in this specification, a circuit comprising therectifying circuit 2 and the smoothing capacitor 3 is called converter.

FIG. 44 shows a general servo control system. Servo control systemcomprises a positional control section 11 for generating a commandconcerning speed from a difference between a positional command valueoutputted from the NC unit 10 and a positional feedback value from amotor edge or a machine edge, a speed control section 12 for generatinga command concerning a current from a difference between a speed commandvalue from the positional control section 11 and a speed feedback value,and a current control section 13 for generating a current provided tothe servo motor 8 from a difference between a current command value fromthe speed control section 12 and a current feedback value from a chantresistor CT. The servo motor 8 rotates and drives a feed screw 16 with areduction gear 15, and linearly moves a table 17 which is an object tobe controlled.

In a case of semi-closed loop, a motor edge detector 18 connected to aservo motor 14 and detecting a rotational speed and a rotational angleof the servo motor 8 and a position of magnetic pole is used, and in acase of full-closed loop, a machine edge position detector 19 fordetecting a position for linear movement of the table 17 is used, and afeedback signal is obtained with the detectors.

FIG. 45 shows a current control section in an AC servo motor. Thiscurrent control section comprises a speed control section 20 foroutputting a q-axis current command value, a limiter 21 for limiting theq-axis current command value outputted from the speed control section 20to protect a semiconductor element constituting a PWM modulating section25 described later, a d-q coordinate converting section 22 forconverting U-phase and V-phase currents outputted to the AC servo motor8 to d-axis and q-axis currents, a current controller 23 a for receivinga difference between a d-axis current command value and a d-axis currentvalue outputted from the d-q coordinate converting section 12 giventhereto and generating a command concerning d-axis voltage so that thedifference is zeroed, a current controller 23 b for receiving adifference between a q-axis current command value outputted from thespeed control section 20 and a q-axis current value outputted from thed-q coordinate converting section 22 given thereto and generating ancommand for q-axis voltage so that the difference is zeroed, a 3-phaseconverting section 24 for subjecting d-axis and q-axis voltage commandsoutputted from the current controllers 23 a and 23 b to three-phaseconversion to generate commands for voltages in U, V and W phases, and aPWM modulating section 25 for generating a 3-phase AC current to beprovided to the AC servo motor 8 from the voltage commands for eachphase outputted from the three-phase converting section 24.

In the configuration as described above, when the NC unit 10 outputs apositional command value, an command concerning speed is generated bythe position control section 11 so that the positional command valuecoincides with a positional feedback value from a motor edge positiondetector 18 in case of a semi-closed loop or from a machine edgeposition detector 19 in case of a full-closed loop, and a q-axis currentcommand is generated by the speed controller 12 so that the speedcommand value will coincide with the speed feedback value detected bythe motor edge position detector 18. In contrast to the q-axis currentcommand, zero (0) is always given to the d-axis current command.

To follow the command, the 3-phase AC current for driving the AC servomotor 8 is finally subjected to PWM modulation by and outputted from thesemiconductor switching circuit 4 shown in FIG. 43 according to theq-axis current command and d-axis current command.

Next, a description is made for operations of a protecting function inthe conventional type of servo motor driver as described above.

As described above, when a q-axis current command is generated to followa positional command from the NC unit 10, if the command value exceedsan allowable current value for the semiconductor switching circuit 4,controls are provided by the limiter 21 to limit the current.

Also if a percentage of a current command value or a phase current valuedetected by the current detecting section 5 against an allowable currentvalue exceeds a certain level and the state continues for a prespecifiedperiod of time, a specific alarm is generated to indicate that thedifference is excessive.

Also if a difference between a positional command value given to thepositional control section and a positional feedback value is largerthan a value deviated by a certain percentage against a logicallycomputed deviation, an alarm indicating that the deviation is excessiveis issued.

Also a current flowing in each transistor in the semiconductor switchingcircuit 4 is detected, and if it is determined that the current isexcessive or a gate shutdown request from a multi-shaft driver or aconverter section, or from an NC unit, a gate for each transistor in thesemiconductor switching circuit is shut down by hardware.

In a full-closed loop having the machine edge detector 19, if adifference between a resolution as well as a number of pulses from themachine edge position detector 19 and a number of pulses presumablycomputed according to a resolution of and a number of pulses from themotor edge position detector 18 so that in normal operating mode amachine edge and a motor edge coincide with each other and thedifference will be zero exceeds an allowable value, it is determinedthat there is abnormality in feedback, and a prespecified alarm isgenerated.

In the conventional type of servo motor driver, there is no function tomonitor a pattern of a current wave form of a current in each phaseflowing in the motor output terminal, so that misconnection of the motoroutput terminal can not be detected, and there is no way but to providean alarm indicating excessive difference or excessive load for stoppingsystem operation, which is disadvantageous.

Also the conventional type of servo motor driver does not have afunction to detect a voltage in each phase loaded to the motor outputterminal, so that it is disadvantageously impossible to detect thatconnection of the motor output terminal or that of a bus-bar for aconverter has not been established.

Also the conventional type of servo motor driver does not have afunction to monitor a gate shutdown signal to a transistor in aninverter section for controlling a current for a servo motor, nor afunction to monitor a type of gate shutdown request signal, so that itis disadvantageously impossible to more detailedly determining causesfor an alarm such as that for an excessive difference or feedbackabnormality.

Also the conventional type of servo motor driver does not have afunction to more detailedly determine, when an alarm indicating anexcessive difference or an excessive load, or abnormality in feedback isgenerated in a full-closed loop having a machine edge position detector,causes for the alarm, and there is no way but to stop system operation,or a long time is required to find out the cause, which isdisadvantageous.

Also the conventional type of servo motor river does not have a meansfor making a determination, when an alarm indicating an excessivedifference or an excessive load is generated during acceleration ordeceleration, as to whether the alarm has been generated because of atime constant for acceleration or deceleration is too small, or becausean abnormal load has been generated, and for this reason there is no waybut to stop system operation even in a case where the system operationcould be continued by automatically readjusting related parameters.

Also the conventional type of servo motor driver does not have afunction to recognize a type of detector, so that if actualspecifications for communications of a detector set with parameters aredifferent from those of a detector actually connected thereto, ano-signal alarm is generated and the state may be mistaken as a fault inthe detector or the connection cable, and in addition a long time isrequired for restoration, and sometimes even very simple mistakes inparameter setting may disable system operation.

SUMMARY OF THE INVENTION

It is an object of the present invention to provide a method ofdetecting and diagnosing abnormalities in a servo control system foraccurately detecting misconnection of a motor output terminal,non-connection of a motor output terminal or a bus-bar for a converter,causes for alarms such as an excessive difference or abnormality infeedback, misconnection of a feedback cable, mis-setting of varioustypes of parameter, mistakes in connection for a detector, shortage in atime constant for acceleration or deceleration, or generation ofabnormal load, for evading system down by automatically restoring thesystem operation by means of automatic correction if any abnormalityoccurs, and furthermore for automatically changing various types ofconditions for servo control so that servo control will be executedunder the optimal conditions.

A method of detecting and diagnosing abnormalities in a servo controlsystem according to the present invention is for detecting through atleast current flowing two phases of U-phase, V-phase, and W-phase of aservo motor output terminal in first acceleration after power is turnedON and monitoring a pattern of a wave form of each current to detectmisconnection of the motor output terminal, and it is an object of thepresent invention to provide a method of detecting and diagnosing aswell as a method for correcting abnormalities in a servo control systemfor accurately detecting misconnection of a motor output terminal,non-connection of a motor output terminal or a bus-bar for a converter,causes for alarms such as an excessive difference or abnormality infeedback, misconnection of a feedback cable, mis-setting of varioustypes of parameter, mistakes in connection for a detector, shortage in atime constant for acceleration or deceleration, or generation ofabnormal load, for evading system down by automatically restoring thesystem operation by means of automatic correction if any abnormalityoccurs, and furthermore for automatically changing various types ofconditions for servo control so that servo control will be executedunder the optimal conditions.

In the method of detecting and diagnosing abnormalities in a servocontrol system according to the present invention, misconnection ofmotor output terminals is detected by detecting currents flowing throughat least two of U-phase, V-phase, and W-phase of a servo output terminalin first acceleration after power is turned ON and monitoring patternsof the current wave forms. With this configuration, it is found out thatthe motor output terminal has been misconnected.

In another method of detecting and diagnosing abnormalities in a servocontrol system according to the present invention, all of U-phase,V-phase, and W-phase currents each flowing in an output terminal of aservo motor and phase voltages are detected, and it is determined thatconnection of the motor output terminal has not been established ifthere is a phase where a current does not flow even though the phasevoltage is more than a prespecified value. With this configuration, itis found out that the motor output terminal has not been connected.

In another method of detecting and diagnosing abnormalities in a servocontrol system according to the present invention, all voltages in eachphase acting on a motor output terminal in acceleration or decelerationare detected, and it is determined, when all the phase voltages arezero, that connection of a bus-bar for a converter has not beenestablished. With this configuration, it is found out that the bus-barfor a converter has not been connected.

In another method of detecting and diagnosing abnormalities in a servocontrol system according to the present invention, a voltage betweeneach phase of an output terminal of a servo motor is detected to computea switching voltage for each phase, and a continuously smooth phasevoltage is detected using a filter to which the computed switchingvoltage is inputted, so that a level of the phase voltage can easily beevaluated.

In another method of detecting and diagnosing abnormalities in a servocontrol system according to the present invention, when a gate shutdownsignal to a transistor in an inverter section providing controls over acurrent for a servo motor is generated when an alarm is not operating, asection where the gate shutdown request signal has been generated isdetected, times when the signal is generated is stored in a memory foreach detected section for a certain period of time in the past, andcauses for an alarm indicating abnormalities in the control system suchas excessive error or abnormality in feedback are determined. With thisconfiguration, it is found out what are causes for an alarm.

In another method of detecting and diagnosing abnormalities in a servocontrol system according to the present invention, in positional controlfor a closed loop system having a machine edge position detector,polarity of signals for a positional command, positional feedback, speedfeedback, a current command, and current feedback is monitored sincepower is turned ON, and if only the positional feedback has a reversepolarity when all the signals are larger than a prespecified value, itis determined that wiring for the feedback cable is not corrected. Withthis configuration, it is found out that wiring for the feedback cableis not corrected.

In another method of detecting and diagnosing abnormalities in a servocontrol system according to the present invention, in positional controlfor a closed loop system having a machine edge position detector, anumber of pulses detected by a motor edge position detector whenmovement is made by a prespecified distance corresponding to rotationsof the motor or other factor is compared upon power turn ON to a numberof detected pulses each indicating a machine edge, and parametermis-setting for machine parameters such as a gear ratio in the machine,a ball screw pitch, resolution of a machine edge position detector orthe like is detected according to a result of this comparison. With thisconfiguration, it is found out that the machine parameters have beenmis-set.

In another method of detecting and diagnosing abnormalities in a servocontrol system according to the present invention, in software forproviding controls over a current for a servo motor, a servo motor modelplotted with d-axis and q-axis current command as input is prepared andwhen an excessive error is indicated even though a difference between apositional feedback value in the model and an actual motor edge positionfeedback value is within a prespecified allowable range, it isdetermined that a constant for acceleration or deceleration is toosmall. With this configuration, it is found out that a constant foracceleration or deceleration is too small.

In another method of detecting and diagnosing abnormalities in a servocontrol system according to the present. invention, in software forproviding controls over a current for a servo motor, a servo motor modelplotted with d-axis and q-axis current commands as input is prepared,and if rotor inertia and load inertia are within an allowable range andsuch a trouble as mis-shutting of a gate has not been generated when adifference between a positional feedback value in the model and anactual motor edge position feedback value exceeds a prespecifiedallowable range, it is determined that abnormal load is present. Withthis configuration, it is found out that abnormal load is present.

In another method of automatically correcting abnormalities in a servocontrol system according to the present invention, positional controlwith a semi-closed loop system is executed when power is turned ON,feedback polarity from the machine edge position detector is determinedduring this period of time, feedback polarity from the machine edgeposition detector is reverted when feedback polarity not coincide with adirection of an instructed position, and then positional control with afull closed loop system is started. With this configuration, systemoperation can be continued without generating an alarm indicating anexcessive error or a feedback fault and without system operation beingstopped.

In another method of automatically correcting abnormalities in a servocontrol system according to the present invention, if a differencebetween a positional feedback rate from a motor edge position detectorand a positional feedback rate from a machine edge position detector ismore than a prespecified value after power is turned ON, feedbackpolarity from the machine edge position detector is reverted. With thisconfiguration, system operation can be continued without systemoperation being stopped.

In another method of automatically correcting abnormalities in a servocontrol system according to the present invention, dual feedback controlis executed, and a difference between a positional feedback rate from amotor edge detector and a positional feedback rate from a machine edgeposition detector after power is turned ON is more than a prespecifiedvalue, feedback polarity from the machine edge position detector isreverted. With this configuration, system operation can be continuedwithout generating an alarm indicating an excessive error or a feedbackfault and without system operation being stopped.

In another method of automatically correcting abnormalities in a servocontrol system according to the present invention, if feedback polarityfrom a machine edge position detector is reverted, the data is stored ina non-volatile memory, and feedback polarity is reverted depending onthe data when power is turned ON again.

With this configuration, in next system operation, system can beoperated in a state where feedback polarity from the machine edgeposition detector is correct from the beginning.

In another method of automatically correcting abnormalities in a servocontrol system according to the present invention, if misconnection ofthe servo motor output terminal is present, a sequence of outputtingvoltage commands is automatically changed. With this configuration, theservo control system can normally be operated even if misconnection ofthe servo motor output terminal is present.

In another method of automatically correcting abnormalities in a servocontrol system according to the present invention, an optimal timeconstant for acceleration or deceleration allowable for an output torquefrom a servo amplifier required for acceleration or deceleration in fastfeed is computed, and a command is prepared with the computed optimaltime constant for acceleration or deceleration in next acceleration ordeceleration. With this configuration, a time constant for accelerationor deceleration is corrected, and a command is prepared with the timeconstant for acceleration or deceleration.

In another method of automatically correcting abnormalities in a servocontrol system according to the present invention, an optimal timeconstant for acceleration or deceleration allowable for an output torqueof a servo amplifier required for acceleration or deceleration in fastfeed is discretely computed for each direction of movement, and acommand is prepared with the computed optimal time constant foracceleration or deceleration for the corresponding direction of movementin next acceleration or deceleration. With this configuration, a timeconstant for acceleration or deceleration is discretely corrected foreach direction of movement, and a command is prepared with the timeconstant for acceleration or deceleration.

In another method of automatically correcting abnormalities in a servocontrol system according to the present invention, an optimal timeconstant for acceleration or deceleration allowable for an output torquefrom a servo amplifier required for acceleration or deceleration in fastfeed is discretely computed for acceleration and decelerationrespectively, and a command is prepared with the corresponding computedoptimal time constant for acceleration or deceleration discretely foracceleration and for deceleration in next acceleration or deceleration.With this configuration, a time constant for acceleration ordeceleration is discretely corrected for acceleration and fordeceleration, and a command is prepared with the time constant foracceleration or deceleration.

In another method of automatically correcting abnormalities in a servocontrol system according to the present invention, an optimal timeconstant for acceleration or deceleration allowable for an output torquefrom a servo amplifier required for acceleration or deceleration in fastfeed is discretely computed for acceleration or for deceleration and foreach direction of movement to always provide a time constant allowablefor an output torque from a servo amplifier required for acceleration orfor deceleration in each feeding direction respectively, and a commandis prepared with the corresponding optimal time constant foracceleration or deceleration and for the corresponding direction in nextacceleration or deceleration. With this configuration, a time constantfor acceleration or deceleration and for each direction of movement isdiscretely corrected, and a command is prepared with the time constantfor acceleration or deceleration.

In another method of automatically correcting abnormalities in a servocontrol system according to the present invention, assuming a case thattime constant for acceleration or deceleration in fast feed is set to asmall value or reaches the maximum output torque from a servo amplifieraffected by abnormal load, a deviation rate of a position fordetermination of the necessity of excessive error alarm (an error froman ideal droop rate) is set to a value larger than an ordinary one onlyduring acceleration or deceleration in fast feed. With thisconfiguration, system operation can be continued without generating anexcessive error alarm.

In another method of automatically correcting abnormalities in a servocontrol system according to the present invention, assuming a case thata time constant for acceleration or deceleration in fast feed is set toa small value or reaches the maximum output torque from a servoamplifier affected by abnormal load, a rotational speed of a motor fordetermination of the necessity for excessive speed alarm is set to avalue larger than an ordinary one only during acceleration ordeceleration in fast feed. With this configuration, system operation canbe continued without generating a speed alarm.

In another method of automatically correcting abnormalities in a servocontrol system according to the present invention, assuming a case thattime constant for acceleration or deceleration in fast feed is set to asmall value or reaches the maximum output torque from a servo amplifieraffected by abnormal load, a maximum speed for a command concerningspeed is clamped at a specified value. With this configuration,overshoot hardly occurs.

In another method of automatically correcting abnormalities in a servocontrol system according to the present invention, a maximum speed for acommand concerning speed is clamped at a specified value only duringacceleration or deceleration. With this configuration, overshoot hardlyoccurs even though time constant for acceleration or deceleration infast feed is set to a small value, or an output torque reaches a maximumtorque from a servo amplifier under influence by an abnormal load.

In another method of automatically correcting abnormalities in a servocontrol system according to the present invention, a maximum speed for acommand concerning speed is clamped at a specified value only while amaximum current for a servo amplifier is being restricted. With thisconfiguration, overshoot hardly occurs even though a time constant foracceleration or deceleration in fast feed is set to a small value, or anoutput torque reaches a maximum output torque from a servo amplifierunder influence by an abnormal load.

In another method of automatically correcting abnormalities in a servocontrol system according to the present invention, if a time constantfor acceleration or deceleration in fast feed is set to a small value,or an output torque reaches a maximum output torque from a servoamplifier under influence by an abnormal load, an command concerningspeed is clamped at a rated rotational speed of a motor, a commandconcerning position for overshooting is thinned out, and the ratethinned out from start of deceleration is distributed and added to eachtime constant. With this configuration, overshoot speed hardly occurs.

In another method of automatically correcting abnormalities in a servocontrol system according to the present invention, a change rate(command concerning speed) of a command concerning position per unittime is suppressed when a current command value has reached a currentlimit value during acceleration in fast feed. With this configuration,overshoot hardly occurs, and an excessive difference alarm hardly begenerated.

In another method of automatically correcting abnormalities in a servocontrol system according to the present invention, when an output torquehas reached a maximum output torque from a servo amplifier during fastfeed under influence by an abnormal load, a positional loop gain isreduced only during the period. With this configuration, systemoperation can be continued without generating an excessive differencealarm.

In another method of automatically correcting abnormalities in a servocontrol system according to the present invention, when an output torquehas reached a maximum output torque from a servo amplifier underinfluence by an abnormal load during fast feed, a positional loop gainis reduced by a specified time constant. With this configuration, systemoperation can be continued without generating an excessive differencealarm.

In another method of automatically correcting abnormalities in a servocontrol system according to the present invention, when an output torquehas reached a maximum output torque from a servo amplifier underinfluence by an abnormal load during fast feed, a positional loop gainwhen a command concerning speed indicates a rated rotational speed of amotor is computed from a current droop rate, and control is provided sothat the command concerning speed will not exceed the rated rotationalspeed of the motor. With this configuration, system operation can becontinued without generating an excessive difference alarm.

In another method of detecting and diagnosing abnormalities in a servocontrol system according to the present invention, a connection state ofa plurality of receiving circuits each for a detector in thetransmitting side thereof is checked when power is turned ON toautomatically detect a type name of a detector actually connectedthereto, and if the type of a detector indicated by the detectedparameter is different from a detector actually connected thereto, aparameter abnormality alarm is generated. With this configuration, it isfound out that a parameter is abnormal.

In another method of automatically correcting abnormalities in a servocontrol system according to the present invention, a connection state ofa plurality of receiving circuits each for a detector in thetransmitting side thereof is checked when power is turned ON toautomatically detect a type name of a detector actually connectedthereto, and if the type of a detector indicated by the detectedparameter is different from a detector actually connected thereto, areceiving circuit is switched to the one corresponding to the connecteddetector. With this configuration, data for a position and speed isprepared by using a detecting circuit corresponding to the detector orwithout generating an alarm indicating non-signal or the like.

Other objects and features of this invention will become understood fromthe following description with reference to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a block diagram showing an embodiment of a servo motor driverused for implementation of the method of detecting and diagnosingabnormalities in a servo control system according to the presentinvention;

FIG. 2 is a flow chart showing a routine for diagnosing connection ofmotor output terminals in the method of detecting and diagnosingabnormalities in a servo control system according to the presentinvention;

FIG. 3A is an explanatory view showing a result of determination ofmisconnection of the motor output terminals;

FIG. 3B is an explanatory view showing a result of determination ofmisconnection of the motor output terminals;

FIG. 4 is a flow chart showing a routine for detecting a phase voltageused for diagnosing connection of the motor output terminal as well as abus-bar for a converter in the method of detecting and diagnosingabnormalities in a servo control system according to the presentinvention;

FIG. 5 is a flow chart showing a routine for diagnosing connection ofthe motor output terminal in the method of detecting and diagnosingabnormalities in a servo control system according to the presentinvention;

FIG. 6 is a flow chart showing a routine for diagnosing connection ofthe bus-bar for a converter in a method of detecting and diagnosingabnormalities in a servo control system according to the presentinvention;

FIG. 7 is a block diagram showing a gate control circuit in a currentcontrol section used for implementation of the method of detecting anddiagnosing abnormalities in a servo control system according to thepresent invention;

FIG. 8 is a flow chart showing a routine for diagnosing causes ofgeneration of a gate shutdown in the method of detecting and diagnosingabnormalities in a servo control system according to the presentinvention;

FIG. 9 is a flow chart showing a routine for diagnosing wiring of afeedback cable in the method of detecting and diagnosing abnormalitiesin a servo control system according to the present invention;

FIG. 10 is a flow chart showing a routine for diagnosing parametersetting in the method of detecting and diagnosing abnormalities in aservo control system according to the present invention;

FIG. 11 is a block diagram showing internal configuration in the currentcontrol section used for implementation of the method of detecting anddiagnosing abnormalities in a servo control system according to thepresent invention;

FIG. 12 is a flow chart showing a routine for diagnosing for searchingcauses while power is being controlled in the method of detecting anddiagnosing abnormalities in a servo control system according to thepresent invention;

FIG. 13 is a flow chart showing a routine for automatically switchingpositions in a position control system in the method of automaticallycorrecting abnormalities in a servo control system according to thepresent invention;

FIG. 14 is a flow chart showing a routine for automatically reverting apolarity in the method of automatically correcting abnormalities in aservo control system according to the present invention;

FIG. 15 is a block diagram showing a servo control system in a dualfeedback control system used for implementation of the method ofautomatically correcting abnormalities in a servo control systemaccording to the present invention;

FIG. 16 is a flow chart showing a routine for automatically reverting apolarity in the servo control system in the dual feedback controlsystem;

FIG. 17 is a block diagram showing an embodiment of the servo controlsystem used for implementation of the method of automatically correctingabnormalities in a servo control system according to the presentinvention;

FIG. 18 is a flow chart showing an embodiment of a routine forcorrecting a time constant in the method of automatically correctingabnormalities in a servo control system according to the presentinvention;

FIG. 19 is a flow chart showing another embodiment of a routine forcorrecting a time constant in the method of automatically correctingabnormalities in a servo control system according to the presentinvention;

FIG. 20 is a flow chart showing another embodiment of a routine forcorrecting a time constant in a method of automatically correctingabnormalities in the servo control system according to the presentinvention;

FIG. 21 is a flow chart showing another embodiment of a routine forcorrecting a time constant in the method of automatically correctingabnormalities in a servo control system according to the presentinvention;

FIG. 22 is a flow chart showing another embodiment of a routine forcorrecting a time constant in the method of automatically correctingabnormalities in a servo control system according to the presentinvention;

FIG. 23 is a flow chart showing another embodiment of a routine forcorrecting a time constant in the method of automatically correctingabnormalities in a servo control system according to the presentinvention;

FIG. 24 is a flow chart showing another embodiment of a routine forcorrecting a time constant in the method of automatically correctingabnormalities in a servo control system according to the presentinvention;

FIG. 25 is a flow chart showing another embodiment of a routine forcorrecting a time constant in the method of automatically correctingabnormalities in a servo control system according to the presentinvention;

FIG. 26 is a flow chart showing another embodiment of a routine forcorrecting a time constant in a method of automatically correctingabnormalities in the servo control system according to the presentinvention;

FIG. 27 is a flow chart showing another embodiment of a routine forcorrecting a time constant in the method of automatically correctingabnormalities in a servo control system according to the presentinvention;

FIG. 28 is a flow chart showing a routine for changing a value ofdetermination of an excessive error in the method of automaticallycorrecting abnormalities in a servo control system according to thepresent invention;

FIG. 29 is a flow chart showing a routine for changing a value ofdetermination of an excessive speed alarm in the method of automaticallycorrecting abnormalities in a servo control system according to thepresent invention;

FIG. 30 is a block diagram showing an embodiment of the servo controlsystem used for implementation of the method of automatically correctingabnormalities in a servo control system according to the presentinvention;

FIG. 31 is a flow chart showing an embodiment of a routine for clampinga command concerning speed in the method of automatically correctingabnormalities in a servo control system according to the presentinvention;

FIG. 32 is a flow chart showing another embodiment of a routine forclamping a command concerning speed in the method of automaticallycorrecting abnormalities in a servo control system according to thepresent invention;

FIG. 33 is a flow chart showing an embodiment of a routine forcontrolling speed as well as a position in the method of automaticallycorrecting abnormalities in a servo control system according to thepresent invention;

FIG. 34 is a graph showing a relation between a command concerning speedand a command concerning a current in a case of using the method ofautomatically correcting abnormalities in a servo control systemaccording to the present invention;

FIG. 35 is a flow chart showing another embodiment of a routine forcontrolling speed as well as a position in the method of automaticallycorrecting abnormalities in a servo control system according to thepresent invention;

FIG. 36 is a flow chart showing another embodiment of a routine forcontrolling speed as well as a position in the method of automaticallycorrecting abnormalities in a servo control system according to thepresent invention;

FIG. 37 is a flow chart showing another embodiment of a routine forcontrolling speed as well as a position in the method of automaticallycorrecting abnormalities in a servo control system according to thepresent invention;

FIG. 38 is a flow chart showing another embodiment of a routine forcontrolling speed as well as a position in the method of automaticallycorrecting abnormalities in a servo control system according to thepresent invention;

FIG. 39A is a block diagram showing a feedback detecting circuit;

FIG. 39B is an explanatory view showing a state of a read port whenthree types of detectors are connected;

FIG. 40 is a circuit diagram showing an example of an exclusive circuitaccording to the present invention;

FIG. 41 is a flow chart showing a routine for diagnosing parameterabnormalities in the method of detecting and diagnosing abnormalities inthe servo control system according to the present invention;

FIG. 42 is a flow chart showing a routine for automatically correcting aconnection state of the detector in the method of automaticallycorrecting abnormalities in a servo control system according to thepresent invention;

FIG. 43 is a block diagram showing a general servo motor driver used ina servo control system;

FIG. 44 is a block diagram showing a general servo control system; and

FIG. 45 is a block diagram showing a current control section of an ACservo motor.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Detailed description is made for embodiments of the present inventionwith reference to the related drawings. It should be noted that the samereference numerals are assigned to the same components as those in theconventional technology and description thereof is omitted.

FIG. 1 shows an embodiment of servo motor driver used for implementationof the method of detecting and diagnosing abnormalities in a servocontrol system according to the present invention. In this servo motordriver, a current detector 5 for detecting a phase current flowing in amotor output terminal detects, in addition to U-phase and V-phasecurrents, a W-phase current.

This servo motor driver has voltage detecting circuits 9 a, 9 b, and 9c. The voltage detecting circuits 9 a, 9 b, 9 c divides a voltagebetween each of the U-phase, V-phase, and W-phase, and outputs a voltagein proportion to a voltage between each phase to an A/D converter. TheA/D converter 6 converts a voltage detected by each of the voltagedetecting circuits 9 a, 9 b, and 9 c to a digital value, and outputs thedigital signal to a CPU 7.

FIG. 2 shows a routine for diagnosing connection of a motor outputterminal in the method of detecting and diagnosing abnormalities in theservo control system according to the present invention.

In this connection diagnosis routine, after power is turned ON, in step101, a q-axis current command Iqa is detected once for every samplingperiod, and then system operation goes to the next step S102.

In Step S102, determination is made as to whether an absolute value ofthe q-axis current command Iqa is more than a prespecified value I_(R)or not, and if it is determined that the absolute value of the q-axiscurrent command Iqa is more than the prespecified value I_(R), it isrecognized that acceleration is required, and then system operation goesto step S104. In contrast, if it is not recognized that acceleration isrequired, system operation goes to step S103.

In step S103, determination is made as to whether an accelerationcommand result flag is ON or not, and if it is determined that theacceleration command result flag is ON, it is recognized that a firstacceleration request is finished. If there is misconnection inconnection for a motor output terminal, the first acceleration requestcontinues until an alarm for an excessive error or an excessive loadalarm is generated, so that, if the acceleration command result flag isON and it is recognized that the first acceleration request is finished,it is recognized that the connection is normal, and the connectiondiagnosis routine is finished. In contrast, if it is determined that theacceleration command result flag is not ON, it is recognized that anacceleration command request has not been generated even though powerhas been turned ON, and system operation returns to step S101.

In step S104, to recognize in step S103 that an acceleration commandrequest is generated after power is turned ON, the acceleration commandresult flag is turned ON, and system operation goes to the next stepS105.

In step S105, a current in each of U-phase, V-phase, and W-phase isdetected once for every sampling period. It should be noted that it isnot always necessary to detect a current flowing through a W-phase, andit is necessary to detect currents in at least two of the three phases,but in this embodiment all currents in the three phases are detected.

In the next step S106, an absolute value of a current in each phasedetected as described above is compared to a peak value up to theprevious operation in the plus side and minus side of current polarityrespectively. As a result of comparison, if it is determined that avalue obtained is higher than or equal to the peak value up to theprevious operation, system operation goes to step S107, and otherwisesystem operation goes to step 109.

In step S107, values recognized as higher than or equal to peak valuesin the plus and minus sides of the current polarity are newly written aspeaks values used for comparison in step S106, and system operation goesto step S108.

In step S108, recognition data of a phase or phases in which valueshigher or equal to peak values in the plus side and minus side of thecurrent polarity respectively are detected are sequentially stored inmemories for the respective values, and system operation goes to thenext step S109.

In step S109, when a quantity of recognition data stored in the previousstep S108 exceeds a certain quantity, system operation goes to the nextstep S110, and otherwise the system step returns to step S101.

In step S110, a patten of current wave form is found out from therecognition data stored in step S108, and determination is made as towhether there is misconnection for the motor output terminal or not.

In a case where a command for acceleration is a request for rotation ofthe motor in the regular direction, as shown in FIG. 3A, if the patternindicates that peak values in currents flowing through U-phase, V-phase,and W-phase are stored in this order with peak values in U-phase asreference in both the plus and minus sides of current polarity, it isdetermined that connection for all of U-, V-, and W-phases is normal,and in contrast, if the pattern indicates that peaks values are storedin the order of U-, W-, and V-phases in both plus and minus sides ofcurrent polarity, it is determined that misconnection causing thesequence of V-, W-, and U-phases or W-, U- and V-phases has beenimplemented.

In a case where a command for acceleration is a request for rotating amotor in the reverse direction, as shown in FIG. 3B, if the patternindicates that peak values of currents flowing through U-phase, W-phaseand V-phase are stored in this order with the peak values in the U-phaseas reference in both the plus and minus sides of current polarity, it isdetermined that connection for U-, V-, and W-phases is correct, and incontrast, if a pattern of U-, V-, and W-phases is indicated, it isdetermined that connection causing an order of V-, W- and U-phases, oran order of W-, U-, and Vphases is present.

In any of the cases above, if a patten of recognition data in the plusside of current polarity does not coincide with that in the minus side,it is determined that there exists other type of misconnection. With thedetermination described above, the connection diagnosis routine isfinished.

With this connection diagnosis routine, misconnection for the motoroutput connection is automatically detected, which makes it possible toprevent operation of the servo control system in a state wheremisconnection for the motor output terminal has not been. corrected.

Also as described above, with this connection diagnosis routine, it ispossible to continue operation by automatically switching a voltagecommand output phase with software after misconnection for U-, V-, andW-phases is identified.

In this case, each voltage command output phase is replaced with eachother by means of software processing according to a result ofdetermination for misconnection as shown in FIGS. 3A, and 3B, so thatthe connection will be a virtually correct one. This is one of theembodiments of automatically correcting abnormalities in a servo controlsystem according to the present invention.

FIG. 4 shows a routine for detecting a phase voltage used for diagnosingconnection of a motor output terminal as well as of a bus-bar for aconverter in the method of detecting and diagnosing abnormalities in aservo control system according to the present invention.

In step S201, each data for a voltage Vuv between a U-phase and aV-phase, a voltage Vvw between a V-phase and a W-phase, and a voltageVwu between a W-phase and a U-phase each detected by the voltagedetecting sections 9 a to 9 c, converted to a digital signal by the A/Dconverter 6 and fetched into the CPU 7, is sampled once for everyspecified period of time.

In the next step S202, switching voltages Vua, Vva, and Vwa are computeddepending on the data.

Vua=(Vuv−Vwu)/3

Vva=(Vvw−Vuv)/3

Vwa=(Vwu−Vvw)/3

The voltages Vua, Vva, and Vwa computed in step S202 are switchingvoltages in the inverter section and discrete data, and to make iteasier to evaluate a level of each phase voltage, in the next step S203,the phase currents are passed through a filter having nominal values foran electromechanical element inductance L and an electromechanicalelement resistance R to obtain continuously smooth phase voltages Vu,Vv, and Vw.

Vu=R·Vua/(Ls+R)

Vv=R·Vva/(Ls+R)

Vw=R·Vwa/(Ls+R)

Herein s indicates a Laplacian operator.

FIG. 5 shows a connection diagnosis routine for a motor output terminalin the method for detecting and diagnosing abnormalities in a servocontrol system according to the present invention. In this motor outputterminal connection diagnosis routine, at first in step S300, i is setto 1, and in step S301 determination is made as to whether a phasevoltage Vi (Vu, Vv, or Vw) is more than a prespecified value V_(R) ornot. If Vi is larger than or equal to V_(R), system operation goes tothe next step S302.

In step S302, a phase current Ii before and after the sampling (Iu, Iv,or Iw) are detected, and in the next step S303, determination is made asto whether the phase current Ii is almost zero or not. If the phase Iiis almost zero, then system operation goes to step S304, and it isdetermined that connection for i-phase has not been established.

As it is defined previously that i is equal to 1 (i=1) in U-phase, equalto 2 (i=2) in V-phase, and equal to 3 (i=3) in W-phase, in steps S301 toS303, the connection diagnosis routine is executed for U-phase, V-phase,and W-phase in this order by determining whether i is larger than orequal to 3 or not in step S305, and updating a phase i to be detected byupdating i to i+1 in step S306.

With this configuration, whether connection of the motor output terminalfor each of U-phase, V-phase, and W-phase has been established or not isautomatically and accurately detected.

FIG. 6 shows a connection diagnosis routine for a bus-bar for aconverter in the method of detecting and diagnosing abnormalities in aservo control system according to the present invention. In thisconverter bus-bar connection diagnosis routine, at first in step S401,whether an absolute value of the q-axis current command Iqa is largerthan a specified value I_(R) or not is determined. If it is determinedthat an absolute value of the q-axis current command Iqa is larger thanthe specified value I_(R), system operation goes to step S402.

In step S402, determination is made as to whether all of the phasevoltages Vu, Vv, and Vw computed in a case where it was recognized instep S401 that an amplifier is demanding acceleration are almost zero ornot. If it is determined that all of the phase voltages Vu, Vv, and Vware almost zero, system operation goes to step S403, and it isdetermined that connection of bus-bar for a converter has not beenestablished.

With this configuration, the fact that connection of bus-bar for aconverter has not been established is automatically and accuratelydetected.

FIG. 7 shows a gate control circuit of a transistor in the semiconductorswitching circuit 4 in a current control section (inverter section) usedfor implementation of the method of detecting and diagnosingabnormalities in a servo control system according to the presentinvention. This gate control circuit has an overcurrent detector 29 fordetecting that an overcurrent flew in the semiconductor switchingcircuit 4.

The CPU 7 fetches a signal indicating that an overcurrent was detectedby the overcurrent detector 29 from a latch circuit 30, a gate-offsignal indicating that a gate shutdown request has been issued from anamplifier or a converter for the other axis from a latch circuit 31, anda gate-off signal from an NC unit from a latch circuit 32 respectively,and a logical product signal for these three signals is obtained by anAND gate 33.

An AND gate 34 is connected to a gate of a transistor Tr in thesemiconductor switching circuit 4, and the AND gate 34 receives anoutput signal from the AND gate 33 and a gate ON/OFF signal outputtedfrom the CPU 7.

In this gate control circuit, the CPU 7 checks an output from each ofthe latch circuits 31, 32 in a case where an overcurrent flows in theinverter section or a gate shutdown request was issued from an amplifierfor other axis or a converter, or where, even though a gate-off (gateshutdown) signal from an NC unit has been generated, no alarm isdetected and a gate-off signal is not issued to the AND gate 34 based onthe recognition that the system is working normally; sets acorresponding flag in a section where the gate shutdown request signalwas generated according to a result of checking above, stores times ofgeneration of the signal for a certain period of time in the past in amemory and determines, if the times exceeds a certain value, that someabnormality exists in the section where the signal was generated. Withthis configuration, a cause for abnormality (a section where theabnormality exists) such as an excessive error, or feedback fault in acontrol system can automatically be detected and determined.

FIG. 8 shows a routine for diagnosing a cause for generation of a gateshutdown request in the method of detecting and diagnosing abnormalitiesin a servo control system according to the present invention.

In this diagnosis routine, in step S451, a gate shutdown request outputstate to the AND gate 34 is monitored with a prespecified cycle, and instep S452, determination is made as to whether a gate shutdown request,namely a gate-off signal is being outputted to the AND gate 34 or not.

If it is determined that a gate shutdown request is not being outputted,system operation goes to step S453, and in step S453, an output state ofeach cause signal from the latch circuits 31, 32 is checked.

Then in step S454, a result of checking of an output state from thelatch circuits 31, 32 is reflected to a gate shutdown signal output flagin the CPU 7, and if the gate shutdown signal output flag is ON, systemoperation goes to step S445, and times of gate shutdown output requestgenerated for each cause of abnormality (times when the gate shutdownsignal output flag is turned ON for each latch circuit) is counted.

In the next step S456, the gate shutdown signal output flag is clearedoff, and in the next step S457, determination is made as to whether acount value for output of gate shutdown request has exceeded aprespecified value or not.

If the count value of gate shutdown request output has exceeded aprespecified value, system operation goes to step S458, and a sectionwhere abnormality causing generation of gate shutdown requests more thana prespecified value exists (for instance, a converter or an NC unit forother axis) is determined.

It should be noted that, if it is determined in step S452 that a gateshutdown request is being outputted, system operation goes to step S459,where determination is made as to whether a specified period of time hasbeen passed or not, and if it is determined that a specified period oftime has passed, system operation goes to step S460, and a count valuefor times of gate shutdown request output is cleared to zero. With thisconfiguration a section where an abnormality such as an excessive erroror feedback fault in the servo control system can quickly be found out.

FIG. 9 shows a wiring diagnosis routine for a feedback cable in themethod of detecting and diagnosing abnormalities in a servo controlsystem according to the present invention. This feedback cable wiringdiagnosis is an application to a servo control system based on the fullclosed loop shown in FIG. 43, and at first in step S501, a positionalcommand value outputted from an NC unit 10, a positional feedback valueoutputted from a machine edge position detector 19, a speed feedbackvalue outputted from a motor edge position detector 18, a currentcommand value outputted from a speed control section 12, a currentfeedback value , and polarity of each signal are always detected andmonitored from power turn ON.

Then in step S502, determination is made as to whether all of thesesignal values are more than a prespecified value respectively, and if itis determined that all of these signal values are more than aprespecified value respectively, system operation goes to step S503.

In step S503, determination is made as to whether only the positionalfeedback value has a reverse polarity or not, and if it is determinedthat only the positional feedback signal has a reverse polarity, systemoperation goes to step S504, and it is determined that wiring for thefeedback cable is not correct.

With this configuration, miswiring for the feedback cable isautomatically and accurately detected.

FIG. 10 shows a parameter setting diagnosis routine in the method ofdetecting and diagnosing abnormalities in a servo control systemaccording to the present invention. In the parameter setting diagnosisroutine, at first in step S701, determination is made as to whetherpolarity of a positional feedback signal is the same as that of apositional command or not, and if it is determined that the two signalshave the same polarity, system operation goes to step S702, and if it isdetermined that the two signals do not have the same polarity, systemoperation goes to step S706.

In step S702, a number of pulses from Z-phase to Z-phase of the motoredge position detector 18 is counted, and whether the number of pulsescoincides with a preset resolution of the motor edge position detectoror not is checked. If it is determined that the setting is correct,system operation goes to the next step S703, and otherwise to step S705.

In step S703, when positioning for a certain feed rate is executed, howmany times the servo motor 8 rotated is computed from a resolution ofthe machine edge position detector 19 and a number of pulses then, and anumber of pulses for one rotation of the motor edge detector 18 iscomputed.

Then in step S704, if a result of checking above indicates that thedetected resolution is X times higher than the actual resolution of themotor edge detector, it is determined that the actual setting is X timeserroneous than the rated setting (X=Gear ratio/resolution of the machineedge position detector/pitch).

In step S705, it is determined that setting of resolution of the motoredge position detector 18 is abnormal.

In step S706, it is determined that wiring for the feedback cable isincorrect.

With this configuration, when a feedback fault occurs in initializationof a machine, determination is made as to whether the fault occurred dueto abnormalities in machine (scale abnormalities), or due to a mistakein parameter setting a gear ratio, or a resolution of a machine edgeposition detector, or a pitch.

FIG. 11 shows internal configuration of a current control section usedin the method of detecting and diagnosing abnormalities in a servocontrol system according to the present invention. This current controlsection corresponds to a current control section 13 in a general servocontrol system as shown in FIG. 43, and comprises, in addition toconfiguration of the conventional type of current control section shownin FIG. 44, a three-phase converting section 26, a torque computingsection 27, and a motor position computing section 28.

The three-phase converting section 26 subjects d-axis and q-axis currentcommand values to three-phase conversion using a magnetic pole positionactually detected from a motor edge as a initial value in the initialstage of acceleration or deceleration, and obtains three-phase currentsIum, Ivm, and Iwm for a motor model. The torque computing section 27computes a model output torque Tem from the model three-phase currentvalues Ium, Ivm, and Iwm outputted from the three-phase convertingsection 26 as well as from a torque constant KT.

The motor position computing section 28 computes a magnetic poleposition θrm of the motor model using the model output torque Temoutputted from the torque computing section 27 and a nominal value forinertia and a number of magnetic poles, and then computes a motor modeloutput torque Tem though the following expression using the three-phasecurrent values Ium, Ivm, and Iwm subjected to three-phase conversion inthe motor model and the magnetic pole position θrm:

Tem={square root over (2/3)}·KT·{−Ium·sin θrm−Ivm·sin (θrm−2π/3)−Iwm·sin(θrm−2π/3) }

From the motor model output torque Tem computed as described above, apositional feedback value θm for the motor model is obtained. Further adifference between a positional feedback value θm for the motor modelobtained as described above and a positional feedback value θ for anactual motor edge is monitored, and when this value is within anallowable range after a current value is limited, it is determined untilimmediately before generation of an alarm indicating an excessive erroror an overload that a constant for acceleration or deceleration is toosmall. With this configuration, shortage of a constant for accelerationor deceleration is recognized.

When the difference between the positional feedback value θm for themotor model and the positional feedback value θ for the actual motoredge exceeds a prespecified value, if an error between an actual valuefor a rotor inertia or a load inertia and a set value is within aallowable range and such an event of incorrect gate shutdown has notoccurred, it is determined that there exists an overload. With thisconfiguration, it is recognized that an overload, namely an abnormalload exists.

FIG. 12 shows a diagnosis routine for searching for a cause when acurrent is limited in the method of detecting and diagnosingabnormalities in a servo control system according to the presentinvention.

In this routine, at first in step S801, a positional feedback value θmfor a motor model is computed.

Then in step S802, determination is made as to whether an alarmindicating an excessive error or an overload has been generated or not,and if it is determined that an alarm indicating an excessive error oran overload has been generated, system operation goes to step S803, anddetermination is made as to whether a current had been limited untilimmediately before generation of the alarm or not.

If it is determined that a current had been limited, system operationgoes to step S804, and determination is made as to whether a positionalfeedback value θm for the motor model and a positional feedback for theactual motor edge is within an allowable range or not.

If it is determined that the difference between the positional feedbackθm for the motor model and the positional feedback θ for the actualmotor edge is within an allowable range, system operation goes to stepS805, and it is determined that a constant for acceleration ordeceleration is too small.

In contrast, if it is determined that the difference between thepositional feedback value θm for the motor model and the positionalfeedback θ for the actual motor edge is not within an allowable range,system operation goes to step S806, and determination is made as towhether a misrequest for gate shutdown or the like has been generated ornot. If it is determined that a misrequest for gate shutdown or the likehas not been generated, system operation goes to step S807, and it isdetermined that there exists an overload.

It should be noted that, in a case wherein it is determined in step S803that a current had not been limited, system operation goes to step S809,and a set value for load inertia for a motor model is checked. With thisdiagnosis routine, diagnosis for adaptability of a constant foracceleration or deceleration and determination for an overload areexecuted.

The method of automatically correcting abnormalities in a servo controlsystem according to the present invention is carried out to a generalservo control system as shown in FIG. 43, and when power for anamplifier is turned ON, of a semi-closed loop system and a full closedloop system, always a semi-closed system is selected for positionalcontrol with a feedback signal from the motor edge position detector 18.Then also a feedback signal from the machine edge position detector 19is processed simultaneously, and checking is executed as to whether anaccumulated range of movement detected by the motor edge detector 18coincides with the polarity or not. If the two parameters coincide,system control shifts to positional control based on a full-closed loopsystem, while if the polarity is reverse, system control automaticallyshifts to positional control based on a full-closed loop system withoutstopping the system operation by reverting positional data accumulatedby the machine edge position detector 19.

FIG. 13 shows a routine for automatically switching a positional controlsystem in the method of automatically correcting abnormalities in aservo control system according to the present invention. In step S1001,as power had just been turned ON, positional control based on asemi-closed loop system is executed.

Then in step S1002, determination is made as to whether an accumulatedrange of movement according to a positional command from the NC unit 10has reached a prespecified value (e.g., 1 mm) or not, namely as towhether a specified range of movement has reached a-range for polaritydetermination by the machine edge position detector 19 or not. If it isdetermined that the accumulated range of movement according to apositional command from the NC unit 10 has reached a prespecified value,system operation goes to step S1002.

In step S1003, an accumulated feedback position in the full-closed loopside is compared to code of an instructed accumulated position, namelychecking is made as to whether polarity of a positional feedback rate ofthe machine edge position detector 19 coincides with that of apositional command or not. If it is determined that polarity of apositional feedback rate of the machine edge detector 19 coincides withthat of a positional command, system operation goes to step S1005, andotherwise to step S1004.

In step S1004, the accumulated feedback rate generated by the machineedge position detector 19 is reverted.

In step S1005, a feedback signal for the accumulated range of movementup to the point of time is switched to the full-closed loop side, andpositional control based on a semi-closed loop system is switched tothat based on a full-closed loop system.

With this configuration, even if polarity of a positional feedback ratefrom the machine edge position detector 19 does not coincide with thatof a positional command when the system is initialized, a system statefor the polarity is automatically corrected, and system operation can becontinued without being stopped.

As described above, positional control can be executed by storingreverse polarity of a feedback from the machine edge position detectorautomatically detected in a non-volatile memory and using the correctfeedback polarity from the first time when power is turned ON again.

However, as there is the possibility that some error to some mechanicalelements such as backlash may be included in the semi-closed loopsystem, it is desirable to add a filter such as that for a primary delayfor switching.

In the method of automatically correcting abnormalities in a servocontrol system according to the present invention, positional controlbased on a full-closed loop system using a machine edge positiondetector 19 is executed since just after power is turned ON, and if theerror with a feedback rate by the motor edge position detector 18becomes larger than a specified value, the system state canautomatically be corrected by reverting a feedback rate by the machineedge position detector 19 up to the point of time.

FIG. 14 shows a routine for automatically reverting polarity in themethod of automatically correcting abnormalities in a servo controlsystem according to the present invention. In step S1101, just afterpower is turned ON, the positional control mode based on a closed-loopsystem is formed as in the ordinary operation. In the next step S1102,checking is made as to whether a difference between a feedback positionPMA in the side of full-closed loop and a feedback position PMO in theside of semi-closed loop has reached a preset reference value CER foridentifying reverse polarity of feedback based on a full-closed loopsystem or not, and also as to whether signs of the two types ofpositional feedback above are contrary to each other or not. If it isdetermined that the difference has reached the reference value CER fordetermination and also that the signs are contrary to each other, systemoperation goes to step S1103.

In step S1103, an accumulated feedback position in the full-closed loopside is reverted, and after that a range of movement is regarded inprocessing as having reverse polarity.

With this configuration, also in this case, even if polarity of apositional feedback rate from the machine edge position detector 19 isreverted when the system is initialized, the system state concerning thepolarity is automatically corrected, and system operation can becontinued without being interrupted.

Also in this case, by storing the automatically detected reversepolarity of feedback from the machine edge position detector 19 in anon-volatile memory, positional control can be carried out with acorrect feedback polarity from the first operation when power is turnedON next.

FIG. 15 shows a servo control system based on a dual feedback controlsystem used for implementation of the method of automatically correctingabnormalities in a servo control system according to the presentinvention. This servo control system has a control section 35 forfiltering for primary delay a difference between a feedback position bythe motor edge position detector 18 and a feedback position by themachine edge position detector 19, and an output from the controlsection 35 is used as an actual positional feedback rate.

This dual feedback control is statically based on a full-closed loopsystem, and is a control for following a difference between positionalfeedback provided by the motor edge position detector 18 and thatprovided by the machine edge position detector 19 with a certain timeconstant, which is applied to a machine with low rigidity.

FIG. 16 shows a routine for automatically reverting polarity in a servocontrol system based on the dual feedback control system describedabove. In step S1201, immediately after power is turned ON, dualfeedback control is formed. Then a time constant for primary delayfilter is set to a value larger than an ordinary set value.

In the next step S1202, checking is made as to whether a differencebetween a feedback position PMA in the full-closed loop side and afeedback position PMO in the semi-closed loop side has reached a presetreference value CER for determination of reverse polarity of feedbackbased on a full-closed loop system, and also as to whether signs of thetwo feedback positions above are contrary to each other or not. If it isdetermined that the difference has reached the reference value CER fordetermination and also that the signs are contrary to each other, systemoperation goes to step S1203.

In step S1203, an accumulated feedback position in the full-closed loopside is reverted, and later a range of movement is processed assumingreverse polarity.

In step S1204, a time constant for the primary delay filter for dualfeedback control is reset to a value in parameter setting, and systemoperation is continued.

With this configuration, even if polarity of a positional feedback rateof the machine edge position detector 19 is reverted, like in this case,when the system is initialized, system state concerning the polarity isautomatically corrected and system operation can be continued withoutbeing interrupted.

Also in this case, by storing reverse polarity of feedback from themachine edge position detector 19 in a non-volatile memory, positionalcontrol can be executed with correct feedback polarity from the firstoperation when power is turned ON again.

FIG. 17 shows an embodiment of a servo control system used forimplementation of the method of automatically correcting abnormalitiesin a servo control system according to the present invention. This servocontrol system includes a control section 36 for clamping a maximumvalue of a current command computed by the speed control section 12.

FIG. 18 shows a routine for correcting a time constant in accelerationor deceleration in the method of automatically correcting abnormalitiesin a servo control system according to the present invention.

At first in step S1501, determination is made as to whether fast feed isnow being executed or not. If it is determined that fast feed is nowbeing executed, system operation goes to step S1502, and a currentcommand value In is sampled. Sampling of this current command value Inis executed at a certain cycle (at max. several ms) during fast feed.

Next in step S1503, an absolute value |In| of the sampled currentcommand value is compared to a maximum value Ip of a current commandsampled up to the previous time during fast feed this time. If |In| islarger, system operation goes to step S1504, and the maximum value Ip ischanged to |In| in the current cycle.

Then in step S1505, determination is made as to whether fast feed in acurrent cycle has been finished or not. “In fast feed” defined hereinindicates a total time required for movement in one operation. When fastfeed is finished, system operation goes to step S1506, and when fastfeed is not finished, system operation returns, after a sampling cycleis over, to step S1502, and then the next current command value In issampled.

In step S1506, a ratio β of a maximum value Ip of a current command in acurrent cycle of fast feed against the maximum current Imax which amotor driver such as a servo amplifier or the like can output iscomputed through the following expression:

β=Ip/Imax

Assuming that an ideal output ratio is α, to get closer an output ratioin acceleration or deceleration in the next cycle of fast feed to anideal output ratio, the time constant B for the next cycle of fast feedis obtained through the following expression:

B=A·β/αA·(Ip/Imax·α)

Herein A is a time constant for fast feed in a current cycle, α is anideal output ratio, and β is a ratio.

The time constant B for acceleration or deceleration obtained as aresult of computing above is substituted into A, and acceleration ordeceleration in the next cycle of operation is executed with this timeconstant.

With this configuration, each time acceleration or deceleration isexecuted, the most suited time constant for acceleration or decelerationcan be computed in real time mode, a time constant for acceleration ordeceleration can automatically be corrected, and acceleration ordeceleration can be realized without the system stability being affectedby change in a load to a machine.

It should be noted that, if a load varies according to a direction ofmovement as in case of an imbalance shaft, it is necessary to decide atime constant using a larger current command value in each operatingdirection.

Also as generally a mechanical load does not change so much, a timeconstant for acceleration or deceleration may be decided depending on anaverage value of maximum values or a peak value for acceleration ordeceleration in several to several tens of operating cycles.Furthermore, generally when power is turned ON in the morning, a machinedoes not work smoothly and a mechanical load becomes largest, so that atime constant in the initial stage after power is turned ON may be setto a value which is around 50% of Imax and then may be correctedautomatically.

FIG. 19 and FIG. 20 show a routine for correcting a time constant suitedto a case where a required torque varies for a direction of movement asin a case of an imbalance shaft.

At first in step S1601, determination is made whether fast feed is nowbeing executed or not. If it is determined that fast feed is beingexecuted, system operation goes to step S1602, and a direction of fastfeed is checked. When fast feed is executed in a + direction, systemoperation goes to step S1603. In contrast, in a case where fast feed isnot executed in the + direction, fast feed is executed in a − direction,so that system operation goes to step S1611. In step S1603, a currentcommand value In is sampled. This sampling of current command value Inis executed once for every cycle (max. several microseconds).

In the next step S1604, an absolute value |In| of the sampled currentcommand value is compared to the maximum value Ip+ of current commandssampled up to the previous operation in a current cycle of fast feed,and if it is determined that |In| is larger, system operation goes tostep S1605, and the maximum value Ip+ is updated to |In| obtained in thecurrent cycle of operation.

Then in step S1606, determination is made as to whether fast feed in acurrent cycle has been finished or not. “In fast mode” defined hereinalso is effective during a total period of time required to movement inone cycle of operation. When fast feed is finished, system operationgoes to step S1607, and when fast feed is not finished, system operationgoes back to step S1603 after a current sampling cycle, and the nextcurrent command value In is sampled.

In step S1607, a ration β of a maximum value Ip + of a current commandin a current cycle of fast feed against the maximum current Imax which amotor driver such as a servo amplifier or the like can output iscomputed through the following expression:

β=(Ip+)/Imax

Assuming that an ideal output ratio is α, to get closer an output ratioin acceleration or deceleration in the next cycle of fast feed to anideal output ratio, the time constant B+ for the next cycle of fast feedis obtained through the following expression:

(B+)=(A+)·β/α=(A+)·{(Ip+)/Imax·α)}

Herein A+ is a time constant for fast feed in a current cycle, α is anideal output ratio, and β is a ratio.

The time constant B+ for acceleration or deceleration obtained as aresult of computing above is substituted into A+, and acceleration ofdeceleration in the+direction in the next cycle of operation is executedwith this time constant.

In step S1609, a current command value In is sampled. Also sampling ofthis current command value In is executed once for every cycle duringfast feed (max. several microseconds).

In the next step S1610, an absolute value |In| of the sampled currentcommand value is compared to the maximum value Ip− of current commandssampled up to the previous operation in a current cycle of fast feed. Ifit is determined that |In| is larger, system operation goes to stepS1611, and the maximum value Ip− is updated to |In| obtained in thecurrent cycle of operation.

Then in step S1612, determination is made as to whether fast feed in acurrent cycle has been finished or not. “In fast mode” defined hereinalso is effective during a total period of time required to movement inone cycle of operation. When fast feed is finished, system operationgoes to step S1613, and when fast feed is not finished, system operationgoes back to step S1609 after a current sampling cycle, and the nextcurrent command value In is sampled.

In step S1613, a ratio β of a maximum value Ip− a current command in acurrent cycle of fast feed against the maximum current Imax which amotor driver such as a servo amplifier or the like can output iscomputed through the following expression:

β=(Ip−)/Imax

Assuming that an ideal output ratio is α, to get closer an output ratioin acceleration or deceleration in the next cycle of fast feed to anideal output ratio, the time constant B for the next cycle of fast feedis obtained through the following expression:

(B−)=(A−)·β/α=(A−)·{(Ip−)/Imax·α)}

herein A− is a time constant for fast feed in a current cycle, α is anideal output ratio, and β is a ratio.

The time constant B− for acceleration or deceleration obtained as aresult of computing above is substituted into A−, and acceleration ordeceleration in the — direction in the next cycle of operation isexecuted with this time constant.

With this configuration, each time acceleration or deceleration isexecuted, a time constant for acceleration or deceleration most suitedto each direction of movement is discretely computed, so that a timeconstant for acceleration or deceleration in each direction of movementcan discretely and automatically be corrected and an operation foracceleration or deceleration can be realized without the systemstability being affected by change in a mechanical load.

As a result, although a time constant for acceleration or decelerationhas been decided with a torque required for an imbalance shaft to go upin the conventional technology, the time constant can be made smallerwhen the imbalance shaft goes down, which makes it possible to reduce atime required for machining.

When a machine is driven, an output torque in acceleration is differentfrom that in deceleration due to a frictional force and an optimal timeconstant for acceleration is different from that for deceleration, sothat automatic correction of time constants for acceleration anddeceleration are executed for acceleration and for decelerationdiscretely in Embodiment 10.

FIG. 21 and FIG. 22 shows a routine for automatically correcting a timeconstant for acceleration or deceleration for acceleration and fordeceleration discretely.

At first, in step S1701, determination is made as to whether fast feedis now being executed or not. If it is determined that fast feed is nowbeing executed, system operation goes to step S1702, and in step S1702,determination is made by checking change in speed change as to whetheracceleration is being executed or not. If it is determined thatacceleration is now being executed, system operation goes to step S1704,otherwise to step S1703.

In step S1703, determination is made by checking change in speed changewhether deceleration is now being executed or not. If it is determinedthat now deceleration is being executed, system operation goes to stepS1709, and otherwise returns to step S1701.

In step S1704, a current command value In is sampled. Sampling of thecurrent command value In is executed once for every specified cycleduring fast feed.

Then in step S1705, an absolute value |In| of the sampled currentcommand value is compared to the maximum value Ipa of current commandssampled up to the previous operation in a current cycle of fast feed. Ifit is determined that |In| is larger, system operation goes to stepS1706, and the maximum value Ipa is updated. to |In| obtained in thecurrent cycle of operation.

Then in step S1707, determination is made as to whether acceleration forfast feed in a current cycle has been finished or not. When accelerationfor fast feed is finished, system operation goes to step S1708 and whenacceleration for fast feed is not finished, system operation goes backto step S1704 after a current sampling cycle, and the next currentcommand value In is sampled.

In step S1708, a ratio β of a maximum value Ipa of a current command ina current cycle of fast feed against the maximum current Imax which amotor driver such as a servo amplifier or the like can output iscomputed through the following expression:

β=(Ipa)/Imax

Assuming that an ideal output ratio is α, to get closer an output ratioin acceleration or deceleration in the next cycle of fast feed to anideal output ratio, the time constant Ba for the next cycle of fast feedis obtained through the following expression:

(Ba)=(Aa)·β/α=(Aa)·{(Ipa)/Imax·α)}

Herein Aa is a time constant for fast feed in a current cycle, α is anideal output ratio, and β is a ratio. The time constant Ba foracceleration obtained through the computing above is substituted intoAa, and acceleration for fast feed in the next cycle is executed withthis time constant.

Also in step S1709, the current command value In is sampled. Sampling ofthe current command value In is executed once for every cycle duringfast feed.

Then in step S1710, an absolute value |In| of the sampled currentcommand value is compared to a maximum value Ip− of a current commandsampled up to the previous cycle during the current fast feed cycle. If|In| is larger, system operation goes to step S1711, and the maximumvalue Ipb is updated to the |In| obtained in the current cycle.

Then in step S1712, determination is made as to whether fast feed in thecurrent cycle has been finished or not. If it is determined that fastfeed has been finished, system operation goes to step S1713, and if itis determined that fast feed has not been finished, system operationreturns after the sampling cycle to step S1709, and the next currentcommand value In is sampled.

In step S1713, a ratio β of a maximum value Ipb of a current command ina current cycle of fast feed against the maximum current Imax which amotor driver such as a servo amplifier or the like can output iscomputed through the following expression:

β=(Ipb)/Imax

Assuming that an ideal output ratio is α, to get closer an output ratioin acceleration or deceleration in the next cycle of fast feed to anideal output ratio, the time constant Bb for the next cycle of fast feedis obtained through the following expression:

(Bb)=(Ab)·β/α=(Ab)·(Ipb)/Imax·α}

herein Ab is a time constant for fast feed in a current cycle, α is anideal output ratio, and β is a ratio.

The time constant Bd for deceleration obtained through the computingabove is substituted into Ab, and deceleration for fast feed in the nextcycle is executed with this time constant.

With this configuration, an optimal time constant for acceleration ordeceleration can discretely be computed in the real time mode each timeacceleration or deceleration is executed, a time constant foracceleration and a time constant for deceleration can automatically becorrected respectively, and an accelerating or decelerating operationcan be realized without the system stability being affected by change inmechanical load.

FIGS. 23 to 27 show a routine for correcting a time constant in which atime constant for acceleration and that for deceleration areautomatically and discretely corrected according to a direction ofmovement.

In step S1801, determination is made as to whether fast feed is beingexecuted or not. If it is determined that fast feed is not beingexecuted now, system operation returns to step S1801, and if it isdetermined that fast feed is being executed, system operations goes tosteps S1802 a to 1802 d.

In steps S1802 a to 1802 d, in which of the following 4 types of modefast feed is being executed is checked.

Namely, in step S1802 a, determination is made as to whetheracceleration is being executed in the + direction or not, and if it isdetermined that acceleration is being executed in the + direction,system operation goes to step S1803.

In step S1802 b, determination is made as to whether acceleration isbeing executed in the − direction or not, and if it is determined thatacceleration is being executed in the − direction, system operation goesto step S1813.

In step S1802 c, determination is made as to whether deceleration isbeing executed in the + direction or not, and if it is determined thatdeceleration is being executed in the + direction, system operation goesto step S1823.

In step S1802 d, determination is made as to whether deceleration isbeing executed in the − direction or not, and if it is determined thatdeceleration is being executed in the − direction, system operation goesto step S1833.

In step S1803, a current command value In is sampled once for everycycle during fast feed.

Then in step S1804, an absolute value |In| of the sampled currentcommand value is compared to a maximum value Ip+a of a current commandsampled up to the previous operation during the current cycle of fastfeed. If |In| is larger, system operation goes to step S1805, and themaximum value Ip+a is updated to |In| obtained in this cycle.

Then in step S1806, determination is made as to whether fast feed in thecurrent cycle has been finished or not. If it is determined that fastfeed in the current cycle has been finished, system operation goes tostep S1807, and if it is determined that fast feed in the current cyclehas not been finished, system operation returns after the sampling cycleto step S1803, and then the next current command value In is sampled.

In step S1807, a ratio β of a maximum value Ip+a of a current command ina current cycle against the maximum current Imax which a motor driversuch as a servo amplifier or the like can output is computed through thefollowing expression:

β=(Ip+a)/Imax

Assuming that an ideal output ratio is α, to get closer an output ratioin acceleration or deceleration in the next cycle of fast feed to anideal output ratio, the time constant B+a for the next cycle of fastfeed is obtained the following expression:

(B+a)=(A+a)·β/α=(A+a)·{(Ip+a)/Imax·α}

Herein A+a is a time constant for fast feed in a current cycle, α is anideal output ratio, and β is a ratio.

The time constant (B+a) for acceleration or deceleration through thecomputing above is substituted into (A+a), and a command foracceleration for fast feed in the + direction in the next cycle isprepared with this time constant.

In step S1813, a current command value In is sampled once for everycycle during fast feed.

Then in step S1814, an absolute value of the sampled current commandvalue |In| is compared to a maximum value Ip−a of a current commandsampled up to the previous cycle during the current fast feed. If |In|is larger, system operation goes to step S1815, and the value Ip−a isupdated to |In| obtained in the current cycle.

Then in step S1816, determination is made as to whether fast feed in thecurrent cycle has been finished or not. If it is determined that fastfeed has been finished, system operation goes to step S1817, and if itis determined that fast feed has not been finished, system operationreturns after the sampling cycle to step S1813, and the next currentcommand value In is sampled.

In step S1817, a ratio β of a maximum value Ip−a of a current command ina current cycle against the maximum current Imax which a motor driversuch as a servo amplifier or the like can output is computed through thefollowing expression:

=(Ip−a)/Imax

Assuming that an ideal output ratio is a α, to get closer an outputratio in acceleration or deceleration in the next cycle of fast feed toan ideal output ratio, the time constant B−a for the next cycle of fastfeed is obtained through the following expression:

(B−a)=(A−a)·β/α=(A−a)·{(Ip−a)/Imax·α}

Herein A−a is a time constant for fast feed in a current cycle, α a isan ideal output ratio, and β is a ratio.

The time constant (B−a) for acceleration or deceleration through thecomputing above is substituted into (A−a), and a command foracceleration for fast feed in the − direction in the next cycle isprepared with this time constant.

In step S1823, a current command value In is sampled once for everycycle during fast feed.

Then in step S1824, an absolute value |In| of the sampled currentcommand value is compared to a maximum value Ipa of a current commandsampled to the previous cycle during the current fast feed. If |In| islarger, system operation goes to step S1825, and the value Ip+d isupdated to |In| obtained in the current cycle.

Then in step S1826, determination is made as to whether fast feed in thecurrent cycle has been finished or not. If it is determined that fastfeed has been finished, system operation goes to step S1827, and if itis determined that fast feed has not been finished, system operationreturns after the sampling cycle to step S1823, and the next currentcommand value In is sampled.

In step S1827, a ratio β of a maximum value Ipd of a current command ina current cycle against the maximum current Imax which a motor driversuch as a servo amplifier or the like can output is computed through thefollowing expression.

β=(Ip+d)/Imax

Assuming that an ideal output ratio is a, to get closer an output ratioin acceleration or deceleration in the next cycle of fast feed, the timeconstant B+d for the next cycle of fast feed is obtained through thefollowing expression:

(B+d)=(A+d)·β/α=(A+d)·{(Ip+d)/Imax·α}

Herein A+d is a time constant for fast feed in a current cycle, α is anideal output ratio, and β is a ratio.

The time constant (B+d) for acceleration or deceleration through thecomputing above is substituted into (A+d), and a command fordeceleration for fast feed in the + direction in the next cycle isprepared with this time constant.

In step S1833, a current command value In is sampled once for everycycle during fast feed.

Then in step S1834, an absolute value |In| of the sampled currentcommand value is compared to a maximum value Ip−d of a current commandsampled up to the previous cycle during the current fast feed. If |In|is larger, system operation goes to step S1835, and the value Ip−d isupdated to Inl obtained in the current cycle.

Then in step S1836, determination is made as to whether fast feed in thecurrent cycle has been finished or not. If it is determined that fastfeed has been finished, system operation goes to step S1837, and if itis determined that fast feed has not been finished, system operationreturns after the sampling cycle to step S1833, and the next currentcommand value In is sampled.

In step S1837, a ratio β of a maximum value Ip−d of a current command ina current cycle against the maximum current Imax which a motor driversuch as a servo amplifier or the like can output is computed through thefollowing expression:

β=(Ip−d)/Imax

Assuming that an ideal output ratio is α, to get closer an output ratioin acceleration or deceleration in the next cycle of fast feed, the timeconstant B−d for the next cycle of fast feed is obtained through thefollowing expression:

(B−d)=(A−d)·β/α=(A−d)·{(Ip−d)/Imax·α}

Herein A−d is a time constant for fast feed in a current cycle, α is anideal output ratio, and β is a ratio.

The time constant (B−d) for acceleration or deceleration through thecomputing above is substituted into (A−d), and a command fordeceleration for fast feed in the − direction in the next cycle isprepared with this time constant.

With this configuration, an optimal time constant for acceleration ordeceleration in each direction can be computed in the real time mode,and an accelerating or decelerating operation can be realized withoutthe system stability being affected by change in a mechanical loadincluding friction.

Even if a time constant for acceleration or deceleration is corrected,when a current command value reaches a limit value, a following error ofa position under servo control is delayed from an ideal value, which maycause overshoot in speed or generation of an alarm indicating anexcessive error, and it may in turn stop system operation.

As a countermeasure against this phenomenon, a value for determinationof an excessive error width in acceleration or deceleration during fastfeed is made variable for making it hard for an excessive error alarm tobe generated.

FIG. 28 shows a routine for changing a reference value for determinationof an excessive error width.

In step S1901, a value DOD for determination of an excessive error widthis a standard value DB. Namely DOB=DB. DB is generally set to around 50%of an ideal droop rate generated during fast feed at the maximum speed(constant state).

In step S1902, determination is made according to a change rate in apositional command value per unit time outputted from a C-device as towhether acceleration or deceleration is being executed during fast feedor not. If it is determined that acceleration or deceleration is beingexecuted during fast feed, system operation goes to step S1903, andotherwise system operation returns to step S1901.

In step S1903, it is assumed that a value for determination of excessiveerror width DOD is equal to DB·a indicates an allowance factor forexcessive error width in acceleration or deceleration, and a is set to avalue larger than 1 (a>1), and generally to around 2.

In step S1904, an ideal droop rate (positional deviation) Di against acurrent command input is computed.

In step S1905, an actual droop rate D at the current point is detected.

Then in step S1906, a difference b between the ideal droop rate Di andactual droop rate D is computed.

Then in step S1907, determination is made as to whether an absolutevalue of the error b of the actual droop rate is more than DOD or not.If it is determined that the absolute value is not more than DOD, systemoperation returns to step S1901 in a certain period of time, and if itis determined that the absolute value is more than DOD, system operationimmediately goes to step S1908.

In step S1908, an alarm indicating an excessive error is generated toeffect emergency stop of the system operation, and NC reset is waited.

In step S1909, determination as to whether an alarm reset request hasbeen issued from an NC unit (actually inputted by an operator) or not,and if it is determined that the request has been issued, systemoperation goes to step S1910.

In step S1910, emergency stop is canceled, and system operation returnsto step S1901.

With this configuration, it becomes possible to provide a servo controlsystem in which an alarm indicating excessive speed is hardly generatedand which has high reliability.

In a case where, although a time constant for acceleration ordeceleration has been corrected, a following error of a position inservo control is delayed from an ideal value because a current commandhas reached a limit value, and overshoot in speed or an excessive erroralarm is generated because of the delay and system operation is stopped,an output current (output torque) inebitably reaches a maximum valuecausing overshoot in speed.

Generally, when a servo motor rotates at a speed around 1.2 times higherthan the rated maximum rotational speed (rpm) of the servo motor, anexcessive speed alarm is generated to protect the system, so that, if aload to a machine unexpectedly increases or changes and the systementers the mode as described above, an alarm is generated.

To cope with the case as described above, a value for determination ofexcessive speed VOS is changed only in acceleration or decelerationduring fast feed so that this alarm will not be generated.

FIG. 29 shows a routine for changing the value for determination of anexcessive speed alarm.

In speed S2001, a rotational speed VOS of a motor used as a referencevalue for determination of alarm for excessive speed is regarded as areference value VB. Generally the VB should preferably be set to around1.2 times of the maximum rotational speed of the motor.

Then in step S2002, determination is made according to a change rate ina positional command per unit time outputted from an NC unit as towhether acceleration or deceleration during fast speed is being executedor not. If it is determined that acceleration or deceleration duringfast speed is being executed, system operation goes to step S2003, andotherwise to step S2004.

In step S2003, a rotational speed VOS of a motor used as a referencevalue for determination of alarm for excessive speed is equal to VB a. ais an allowance factor for excessive speed in acceleration ordeceleration, and a is set to a value larger than 1, and generally toaround 1.2.

Then in step S2004, an actual rotational speed V of a motor is detected.

Then in step S2005, determination is made as to whether the actualrotational speed of motor (rpm) V is more than the value VOS fordetermination of excessive speed alarm or not. If it is determined thatthe actual rotational speed of motor is not more than the value VOS,system operation returns to step S2001 in a certain period of time, andotherwise immediately to step S2006.

In step S2006, an excessive speed alarm is generated to effect emergencystop, and NC reset is waited.

In step S2007, determination is made as to whether an alarm resetrequest has been issued from an. NC unit (actually inputted by anoperator), and if it is determined that an alarm reset request has beenissued, system operation goes to step S2008.

In step S2008, emergency stop is canceled, and system operation returnsto step S2001.

With this configuration, it becomes possible to provide a servo controlsystem in which an excessive speed alarm is hardly generated and whichhas high reliability.

FIG. 30 shows an embodiment of a servo control system for implementationof the method of automatically correcting abnormalities in a servocontrol system according to the present invention. This servo controlsystem includes a control section 37 for clamping a maximum value of aspeed command computed by the positional control section 11.

With this configuration, even if a current reaches a limit value, anovershoot rate can be suppressed by clamping a speed command at aspecified value V_(MAX) (a value around 1.2 times higher than themaximum rotational speed of the motor).

In this embodiment, an overshoot rate is suppressed by clamping a speedcommand only in acceleration or deceleration during fast feed, so thatsuch a work as high speed cutting will not be affected and followabilityto a command with high acceleration will not be sacrificed.

FIG. 31 shows a speed command clamp routine in this embodiment.

At first in step S2201, clamping of a speed command is canceled.

Then in step S2202, determination is made according to a change rate ina positional command per unit time outputted from an NC unit whetheracceleration or deceleration during fast feed is being executed or not.If it is determined that acceleration or deceleration is being executed,system operation goes to step S2203, and otherwise system operationreturns to step S2201. In step S2203, because acceleration ordeceleration is being executed during fast feed, a maximum clamp valuefor a speed command is set to V_(MAX).

In step S2204, determination is made as to whether a speed commandcomputed for positional control exceeds V_(MAX) or not. If it isdetermined that a speed command exceeds V_(MAX), system operation goesto step S2205, where an absolute value of the speed command is outputtedas V_(MAX), and then system operation returns to step S2201.

With this configuration, a maximum speed for a speed command is clampedat a specified value only during acceleration or deceleration, so thatovershoot hardly occurs even when an output torque from a servoamplifier has reached a maximum value under influence by an abnormalload.

In this embodiment, a speed command is clamped only when a currentcommand value has reached its limit.

FIG. 32 shows a speed command clamping routine in this embodiment.

In step S2301, clamping of a speed command is canceled, and then in stepS2302, a current command value In is sampled.

Then in step S2303, determination is made as to whether a currentcommand value In has reached a current limit value or not. If it isdetermined that the current command value In has reached a current limitvalue, system operation goes to step S2304, and if it is determined thatthe current command value In has not reached a current limit value,system operation goes to step S2305.

In step S2304, V MAX is a maximum clamp value for a speed command.

In step S2305, determination is made as to whether a speed commandcomputed for positional control has reached V MAX or not. If it isdetermined that a speed command has reached V MAX, system operation goesto step S2306, where an absolute value of a speed command is outputtedas V MAX, and system operation returns to step S2301.

With this configuration, it becomes possible to provide a highreliability servo control system in which overshoot hardly occurs evenwhen an output torque from a servo amplifier has reached its maximumvalue because a time constant set for acceleration or decelerationduring fast feed is too small, or due to influence by an abnormal load.

[Embodiment 18]

In this embodiment, the function for clamping a speed when a currentcommand value has reached its limit value in acceleration during fastfeed is further enhanced, a positional droop rate for overshooting as aspeed command is thinned and distributed and added to a time constantfor deceleration from a point of time when deceleration is started.

FIG. 33 shows an operation flow in this embodiment.

In step S2401, determination is made as to whether fast feed is beingexecuted or not. If it is determined that fast feed is being executed,system operation goes to step S2402, and otherwise returns to stepS2401.

In step S2402, determination is made as to whether a current commandvalue has reached a current limit value thereof or not. If it isdetermined that the current command value has reached the limit value,system operation goes to step S2403, and otherwise returns to stepS2401.

In step S2403, a speed command is clamped at the maximum rotationalspeed V_(MO) of the motor. And, a maximum positional droop rate D_(max)obtained by computing a positional loop gain from V_(MO) is compared toa real droop rate D, and a positional droop section D_(ER) for asurpassing section is thinned out from the positional command duringaccerelation, and deceleration is waited.

In step S2404, determination is made as to whether deceleration is beingexecuted or not, and if it is determined that deceleration is started,system operation goes to step S2405.

In step S2405, the positional command data D_(ER) thinned out from apoint of time when deceleration is started is added in deceleration.

A relation between the speed command controlled as described above and acurrent command is shown in FIG. 34.

With this configuration, it becomes possible to obtain a stable and highreliable servo control system in which overshoot hardly occurs even whena time constant set for acceleration or deceleration during fast feed istoo small or when a torque output from a servo amplifier has reached themaximum value due to influence by an abnormal load.

In this embodiment, when a current command value has reached a currentlimit value in acceleration during fast feed, by shifting a positionalcommand per unit time (command speed) to a lower level, it becomes hardfor overshoot to be generated and for an excessive error alarm to beissued. It should be noted that, in a case of operation interpolatingbetween a plurality of axes, this operation is executed for movement notto be off from each of the axes.

FIG. 35 shows an operation flow in this embodiment.

In step S2501, determination is made as to whether fast feed is beingexecuted or not. If it is determined that fast feed is being executed,system operation goes to step S2502, and otherwise returns to stepS2501.

In step S2502, determination is made as to whether a current commandvalue has reached a current limit value or not. If it is determined thata current command value has reached a current limit value, systemoperation goes to step S2503.

In step S2503, a change rate of positional command per unit time islimited so that a current command of a servo model set in an NC unitwill not be above a level of the current limit value. Namely apositional command is thinned. If control over a current is canceled,shortage in a positional command due to thinning at the point of time issupplemented by a time constant or by means of time distribution toobtain a correct absolute position.

With this configuration, it becomes harder for overshoot to be generatedand for an excessive error alarm to be issued.

In this embodiment, when an output torque from a servo amplifier is atthe maximum value thereof during fast feed due to influence by anabnormal load, positional loop gains for all axes are lowered onlyduring the period so that such a fault as an excessive error will notoccur.

FIG. 36 shows an operation flow in this embodiment. It should be notedthat generally a torque required for acceleration is larger than thatrequired for deceleration, and for this reason the following descriptionis focused on acceleration.

In step S2601, determination is made as to whether fast feed is beingexecuted or not. If it is determined that fast feed is being executed,system operation goes to step S2602.

In step S2602, determination is made as to whether a current commandvalue has reached a current limit value or not. If it is determined thata current command has reached a current limit value, system operationgoes to step S2603.

In step S2603, in a state where a droop rate becomes larger than anideal value, at a point of time when a positional loop gain for an axiswhere an NC unit has reached a current limit for a servo amplifiercontrol section is gradually lowered and restriction of a current isreleased, if system operation is stabilized at a fixed level or at acertain speed during fast feed, the positional loop gain is graduallyreturned to the original value.

With this configuration, in a case where an output torque from a servoamplifier has reached the maximum value due to influence by an abnormalload, positional loop gains for all axes are lowered only during theperiod, so that movement of the servo system becomes slower and systemoperation can be continued without such a fault as excessive error beinggenerated.

In this embodiment, in a case where an output torque from a servoamplifier has reached the maximum value due to influence by an abnormalload during fast feed, positional loop gains for all axes are lowered bya time constant, this operation for changing the positional loop gainsis stopped at a point of time when restriction over a current iscanceled, and control is provided with the same gain until movement isfinished. In the next operation, as a time constant for fast feed ischanged according to the method of correcting a time constant foracceleration or deceleration as described above, movement is startedwith the positional loop gain originally set.

FIG. 37 shows an operation flow in this embodiment. Generally a torquerequired for acceleration is larger than that required for deceleration,so that the following description is focused on acceleration.

In step S2701, determination is made as to whether fast feed is beingexecuted or not. If it is determined that fast feed is being executed,system operation goes to step S2702.

In step S2702, determination is made as to whether a current commandvalue has reached a current limit value or not. If it is determined thata current command has reached a current limit value, system operationgoes to step S2703.

In step S2703, in a state where a droop rate becomes larger than anideal value, at a point of time when a positional loop gain for an axiswhere an NC unit has reached a current limit for a servo amplifiercontrol section is gradually lowered with a certain time constant andrestriction of a current is released, if system operation is stabilizedat a fixed level or at a certain speed, the positional loop gain isgradually returned to the original value.

With this configuration, system operation can be continued withoutgenerating an excessive error alarm.

In this embodiment, in a case where an output torque from a servoamplifier has reached the maximum value due to influence by an abnormalload during fast feed, a positional loop gain when a speed command hasreached a value V (V=a value corresponding to a rated rotational speedof motor +α: α is around 2% of the rated rotational speed (rpm) of themotor) is computed from the current droop rate, so that a speed commandwill not be more than the value V.

In FIG. 38 shows an operation flow in this embodiment. Generally atorque required for acceleration is larger than that required fordeceleration, so that the following description is focused onacceleration.

In step S2801, determination is made as to whether fast feed is beingexecuted or not. If it is determined that fast feed is being executed,system operation goes to step S2802.

In step S2802, determination is made as to whether a current commandvalue has reached a current limit value or not. If it is determined thata current command has reached a current limit value, system operationgoes to step S2803.

In step S2803, in a state where a droop rate becomes larger than anideal value, at a point of time when a positional loop gain Kp for anaxis where an NC unit has reached a current limit for a servo amplifiercontrol section is lowered to a value computed through the followingexpression and restriction of a current is released, if system operationis stabilized at a fixed level or at a certain speed, the positionalloop gain Kp is gradually returned to the original value.

Kp=(Rated rpm of a motor+α)/60·D Herein D indicates a droop rate.

With this configuration, system operation can be continued withoutgenerating an excessive error alarm also in this embodiment.

In association with introduction of a detector based on absolutepositions used for positional feedback and development of technology forhigher resolution, there have become available many and various types ofI/F method, and it is necessary to use as many receiving lines aspossible to respond to every type of detector.

In this embodiment, there are receiving lines corresponding to threedifferent types of detector I/F, type of connected detectors areautomatically determined upon power turn ON and not depending on servoparameters set in the detectors, and a parameter abnormal alarm isgenerated when a detector type specified by a parameter is differentfrom that actually connected.

FIG. 39A shows an example of feedback detection circuit. Shared in thisfeedback detection circuit are I/O circuits of three different types ofdetector: an incremental detector having A-, B-, and Z- phases requiredfor control of pulse output position and speed control + U-, V-, and W-phases for initial magnetic poles of a synchronizing motor, an absoluteposition detector initially sending and receiving (RQ and DT) anabsolute position through serial communications and then executingcommunications through the A-, B-, and Z- phases, and a detector alwayssending and receiving data concerning absolute positions by means ofserial communications (only RQ and DT).

FIG. 39A shows differential inputs to A-phase, B-phase, Z-phase,U-phase, V-phase, and W-phase from the left top. In this example, theU-phase and RQ (serial data request), and V-phase and DT (serial dataline) are shared respectively.

This feedback detection circuit comprises differential receivers 171 ato 171 f, exclusive circuits 172 a to 172 f for detecting a fact that adifferential input is connected, an incremental counter (a counter forpreparing a feedback rate) 173 for counting pulses for each of the A-,B-, and Z-phases, a serial request I/F circuit 174 for supporting arequest portion in the serial communications, a receiving buffer (serialdata receiving I/F circuit) 175 for storing data from the detectors, aU-, V, and W- phases read port 176 for monitoring a state of each of theU-, V-, and W-phases for initial magnetic pole, and a read port 177 forreading a null signal state for each phase to monitor a null signalstate in each phase. It should be noted that, as a terminator resistanceis connected, as shown in FIG. 40, to the exclusive circuit, output fromthe exclusive circuit is always 1 in the open state.

FIG. 39B shows a state of the read port 177 in a case where the threetypes of detectors are connected thereto.

A driver enable line in the serial detector request line is disabledwhen power is turned ON, and if each detector determines that 6 inputstates are all normal, data as shown in FIG. 39B is obtained. This datais compared for verification to parameters of each detector type namesent from the NC unit, and if different, a parameter abnormal alarm isgenerated.

FIG. 41 shows the parameter abnormal diagnosis outine.

At first, in step S2901, all phases are specified s input lines, andthen in the next step S2902, a null signal state is checked.

Then in step S2903, a connected detector is determined according to aresult of null-signal state.

In step S2904, a parameter indicating a detector type name is comparedfor verification to a connected detector.

In step S2905, determination is made as to whether aparameter.indicating a detector type name is identical to the connecteddetector or not. If not identical, system operation goes to step S2906,and a parameter abnormal alarm is generated to stop the systemoperation.

With this configuration, if a detector type indicated by a parameter isdifferent from a detector actually connected, an parameter abnormalalarm is generated, which makes easier to search for a cause of fault,if generated.

In this embodiment, if it is turned out through the sequence forautomatic determination described above that a detector specified by aparameter is different from an actually connected detector, I/F isswitched to one for the actually connected parameter to automaticallycorrect abnormality in detector connection state.

FIG. 42 shows an operation flow in this embodiment.

At first, in step S3001, all phases are specified as input lines, andthen in the next step S3002, a null-signal state is checked.

Then in step S3003, a connected detector is determined according to aresult of null-signal state.

In step S3004, a parameter indicating a detector type name is comparedfor verification to a connected detector.

In step S3005, determination is made as to whether a parameterindicating a detector type name is identical to the connected detectoror not. If not identical, system operation goes to step S3006, and asetting in the sending and receiving sections are adjusted to I/F for adetector determined as connected thereto.

With this configuration, a detection circuit adjusted to a detectordetected thereto in which an alarm such as null-signal is not generatedeven when there is any mistake in parameter setting can be formed, whichinsures normal operation of the system.

As described above, in the method of detecting and diagnosingabnormalities in a servo control system according to the presentinvention, misconnection of motor output terminals is detected bydetecting currents flowing through at least two of U-phase, V-phase, andW-phase of a servo output terminal in first acceleration after power isturned ON and monitoring patterns of the current wave forms, so that itis accurately found out that the motor output terminal has beenmisconnected.

In another method of detecting and diagnosing abnormalities in a servocontrol system according to the present invention, all of U-phase,V-phase, and W-phase currents each flowing in an output terminal of aservo motor and phase voltages are all detected, and it is determinedthat connection of the motor output terminal has not been established ifthere is a phase where a current does not flow even though the phasevoltage is more than a prespecified value, so that it is found out thatthe motor output terminal has not been connected.

In another method of detecting and diagnosing abnormalities in a servocontrol system according to the present invention, all voltages in eachphase acting on a motor output terminal in acceleration or decelerationare detected, and it is determined, when all the phase voltages arezero, that connection of a bus-bar for a converter has not beenestablished, so that it is found out that the bus-bar for a converterhas not been connected.

In another method of detecting and diagnosing abnormalities in a servocontrol system according to the present invention, a voltage betweeneach phase of an output terminal of a servo motor is detected to computea switching voltage for each phase, and the phase voltage is detectedusing a filter to which the computed switching voltage is inputted, sothat a phase voltage of which a level can easily be evaluated can beobtained, and detecting and diagnosing abnormalities using the phasevoltage can accurately be executed.

In another method of detecting and diagnosing abnormalities in a servocontrol system according to the present invention, a gate shutdownsignal to a transistor in an inverter section providing controls over acurrent for a servo motor is monitored and a generated section thereofis detected, so that causes for an alarm indicating abnormalities in thecontrol system such as an excessive error or a feedback fault can befound, which can smoothly be coped with thereafter.

In another method of detecting and diagnosing abnormalities in a servocontrol system according to the present invention, in positional controlfor a closed loop system having a machine edge position detector,polarity of signals for a positional command, positional feedback, speedfeedback, a current command, and current feedback is monitored sincepower is turned ON, and if only the positional feedback has a reversepolarity when all the signals are larger than a prespecified value, itis determined that wiring for the feedback cable is miscorrected, sothat it is accurately found out that wiring for the feedback cable ismiscorrected.

In another method of detecting and diagnosing abnormalities in a servocontrol system according to the present invention, in positional controlfor a closed loop system having a machine edge position detector, anumber of pulses detected by a motor edge position detector whenmovement is made by a prespecified distance corresponding to rotationsof the motor or other factor is compared upon power turn ON to a numberof detected pulses each indicating a machine edge, and parametermissetting for machine parameters such as a gear ratio in the machine, aball screw pitch, resolution of a machine edge position detector or thelike is detected according to a result of this comparison, so that it isaccurately found out that the machine parameters have been misset, andthe efficiency of a period of time to adjust for initiating a machinecan be improved.

In another method of detecting and diagnosing abnormalities in a servocontrol system according to the present invention, in software forproviding controls over a current for a servo motor, a servo motor modelplotted with d-axis and q-axis current command as input is prepared andwhen an excessive error is indicated even though a difference between apositional feedback value in the model and an actual motor edge positionfeedback value is within a prespecified allowable range even after acurrent is restricted, it is determined that time constant foracceleration or deceleration is too small, so that it is accuratelyfound out that time constant for acceleration or deceleration is toosmall.

In another method of detecting and diagnosing abnormalities in a servocontrol system according to the present invention, in software forproviding controls over a current for a servo motor, a servo motor modelplotted with d-axis and q-axis current commands as input is prepared,and if a rotor inertia and a load inertia are within an allowable rangeand such a trouble as misshutting of a gate has not been generated whena difference between a positional feedback value in the model and anactual motor edge position feedback value exceeds a prespecifiedallowable range, it is determined that abnormal load is present, so thatit is accurately found out that abnormal load is present.

In another method of automatically correcting abnormalities in a servocontrol system according to the present invention, even though feedbackpolarity from a machine edge position detector for positional controlwith a semi-closed loop system is reverted in the first place,positional control with a full closed loop system is started byautomatically correcting the feedback polarity, so that system operationcan be continued without generating an alarm indicating an excessivedifference or a feedback fault and without being stopped. With thisconfiguration, a servo control system with high reliability withoutbeing affected from parameter setting or misconnection executed by auser can be realized.

In another method of automatically correcting abnormalities in a servocontrol system according to the present invention, even if feedbackpolarity from a machine edge detector is reverted, it is automaticallycorrected, so that system operation can be continued without generatingan alarm indicating an excessive difference or feedback abnormalitiesand without being stopped. With this configuration, a servo controlsystem with high reliability without being affected from parametersetting or misconnection executed by a user can be realized.

In another method of automatically correcting abnormalities in a servocontrol system according to the present invention, dual feedback controlis executed to determine feedback polarity from a machine edge positiondetector, and even if feedback polarity from the machine edge positiondetector is reverted, it is automatically corrected, so that systemoperation can be continued without generating an alarm indicating anexcessive difference or a feedback fault and without being stopped. Withthis configuration, a servo control system with high reliability withoutbeing affected from parameter setting or misconnection executed by auser can be realized.

In another method of automatically correcting abnormalities in a servocontrol system according to the present invention, if a state wherefeedback polarity from a machine edge position detector is reverted isdetected, the data is stored in a non-volatile memory, and feedbackpolarity is reverted and controlled depending on the data when power isturned ON again, and for this reason, an intelligent servo controlsystem with high reliability can be realized so that even if there isany mistakes in setting or connection, it can be automatically correctedthereby.

In another method of automatically correcting abnormalities in a servocontrol system according to the present invention, if misconnection ofthe servo motor output terminal is present, a sequence of outputtingvoltage commands is changed in the order of correct phase, so that theservo control system can normally be operated without any change ofconnection, and an intelligent servo control system automaticallycorrecting misconnection executed by a user can be realized.

In another method of automatically correcting abnormalities in a servocontrol system according to the present invention, an optimal timeconstant allowable for an output torque from a servo amplifier requiredfor acceleration or deceleration in fast feed is computed, and a commandis prepared with the computed optimal time constant in next accelerationor deceleration, so that an optimal time constant in accordance with thechange can be obtained even if a mechanical load is changed.

In another method of automatically correcting abnormalities in a servocontrol system according to the present invention, an optimal timeconstant allowable for an output torque of a servo amplifier requiredfor acceleration or deceleration in fast feed is computed for eachdirection of movement (a feed direction), and a command is prepared withthe computed optimal time constant for the corresponding direction ofmovement in next acceleration or deceleration, so that an optimal timeconstant for acceleration or deceleration can always be obtainedaccording to the direction of movement even if an axis of moving up anddown is a load imbalance axis.

In another method of automatically correcting abnormalities in a servocontrol system according to the present invention, an optimal timeconstant allowable for an output torque from a servo amplifier requiredfor acceleration or deceleration in fast feed is computed foracceleration and deceleration respectively, and an command is preparedwith the corresponding computed optimal time constant in thecorresponding direction in next acceleration or deceleration, so thattime constant for deceleration can be set to a small value becausetorque can be accelerated by normal friction, and required time foracceleration or for deceleration can be shortened.

In another method of automatically correcting abnormalities in a servocontrol system according to the present invention, an optimal timeconstant allowable for an output torque from a servo amplifier requiredfor acceleration or deceleration in fast feed is always computed foracceleration or for deceleration and for each direction of movement, anda command is prepared with the corresponding optimal time constant innext acceleration or deceleration, so that an optimal time constant foracceleration or deceleration corresponding to all the changings such asload imbalance (such as gravity), friction, and time can be obtained.

In another method of automatically correcting abnormalities in a servocontrol system according to the present invention, assuming a case thattime constant for acceleration or deceleration in fast feed is set to asmall value or reaches the maximum output torque from a servo amplifieraffected by abnormal load, a deviation rate of a position fordetermination of the necessity of excessive error alarm is set to avalue larger than an ordinary one only during acceleration ordeceleration. in fast feed, so that an alarm indicating an excessiveerror hardly occurs, and a servo control system with high reliabilitycan be realized.

In another method of automatically correcting abnormalities in a servocontrol system according to the present invention, assuming a case thattime constant for acceleration or deceleration in fast feed is set to asmall value or reaches the maximum output torque from a servo amplifierunder influence by an abnormal load, a rotational speed of a motor fordetermination of the necessity for excessive speed alarm is set to avalue larger than an ordinary one only during acceleration ordeceleration in fast feed, so that excessive speed alarm hardly occurs,and a servo control system with higher reliability as compared to theconventional type thereof can be provided.

In another method of automatically correcting abnormalities in a servocontrol system according to the present invention, assuming a case thattime constant for acceleration or deceleration in fast feed is set to asmall value or reaches the maximum output torque from a servo amplifierunder influence by an abnormal load, a maximum speed for a commandconcerning speed is previously clamped at a specified value, so thatovershoot can be suppressed, and an excessive error or excessive speedalarm hardly occurs, and a reliable and stable servo control system canbe obtained.

In another method of automatically correcting abnormalities in a servocontrol system according to the present invention, a maximum speed for acommand concerning speed is clamped at a specified value only duringacceleration or deceleration, so that overshoot hardly occurs even iftime constant for acceleration or deceleration in fast feed is set to asmall value, or an output torque reaches a maximum output torque from aservo amplifier under influence by an abnormal load, and a reliable andstable servo control system can be obtained.

In another method of automatically correcting abnormalities in a servocontrol system according to the present invention, a maximum speed for acommand concerning speed is clamped at a specified value only while amaximum current for a servo amplifier is being restricted, so thatovershoot hardly occurs even if time constant for acceleration ordeceleration in fast feed is set to a small value, or an output torquereaches a maximum output torque from a servo amplifier under influenceby an abnormal load, and a reliable and stable servo control system canbe obtained.

In another method of automatically correcting abnormalities in a servocontrol system according to the present invention, if time constant foracceleration or deceleration in fast feed is set to a small value, or anoutput torque reaches a maximum output torque from a servo amplifierunder influence by an abnormal load, an command concerning speed isclamped at a rated rotational speed of a motor, a command concerningposition for overshooting is thinned out, and the rate thinned out fromstart of deceleration is distributed and added to each time constant, sothat overshoot hardly occurs, and a reliable and stable servo controlsystem can be obtained.

In another method of automatically correcting abnormalities in a servocontrol system according to the present invention, a change rate(command concerning speed) of a command concerning position per unittime is suppressed when a current command value has reached a currentlimit value during acceleration in fast feed, so that an excessive erroralarm hardly occurs and also overshoot hardly occurs, and a reliable andstable servo control system can be obtained.

In another method of automatically correcting abnormalities in a servocontrol system according to the present invention, when a currentcommand value has reached a maximum output torque from a servo amplifierduring fast feed under influence by an abnormal load, a positional loopgain is reduced only during the period to smoothly operate movement ofthe servo system, and for this reason a reliable servo control systemcan be obtained so that system operation can be continued withoutgenerating an excessive error.

In another method of automatically correcting abnormalities in a servocontrol system according to the present invention, when an output torquehas reached a maximum output torque from a servo amplifier underinfluence by an abnormal load during fast feed, a positional loop gainis reduced by a specified time constant, and for this reason a reliableservo control system can be obtained so that system operation can becontinued without generating an excessive error alarm.

In another method of automatically correcting abnormalities in a servocontrol system according to the present invention, when a currentcommand value has reached a maximum output torque from a servo amplifieraffected by abnormal load during fast feed, a positional loop gain whena command concerning speed indicates a rated rotational speed of a motoris computed from a current droop rate, and control is always provided sothat the command concerning speed will not exceed the rated rotationalspeed of the motor, and for this reason a servo control system wheresystem operation can be continued without generating an excessive erroralarm can be obtained.

In another method of automatically correcting abnormalities in a servocontrol system according to the present invention, a connection state ofa plurality of receiving circuits each for a detector in thetransmitting side thereof is checked when power is turned ON toautomatically detect a type name of a detector actually connectedthereto, and if the type of a detector indicated by the detectedparameter is different from a detector actually connected thereto, aparameter abnormality alarm is generated, and for this reason a reliableservo control system can be obtained so that causes when some fault hasbeen generated can easily be analyzed.

In another method of automatically correcting abnormalities in a servocontrol system according to the present invention, a connection state ofa plurality of receiving circuits each for a detector in thetransmitting side thereof is checked when power is turned ON toautomatically detect a type name of a detector actually connectedthereto, and if the type of a detector indicated by the detectedparameter is different from a detector actually connected thereto, areceiving circuit is switched to the one corresponding to the connecteddetector, and for this reason an intelligent and reliable servo controlsystem can be obtained so that system can normally start up itsoperation even if any mistake is found in parameter setting.

Although the invention has been described with respect to a specificembodiment for a complete and clear disclosure, the appended claims arenot to be thus limited but are to be construed as embodying allmodifications and alternative constructions that may occur to oneskilled in the art which fairly fall within the basic teaching hereinset forth.

What is claimed is:
 1. A method of automatically correctingabnormalities in a servo control system comprising the step of: reducinga positional loop gain only during a period in which a current commandvalue has reached a current limit value during fast feed.
 2. A method ofautomatically correcting abnormalities in a servo control systemcomprising the step of: reducing a positional loop gain by a specifiedtime constant only during a period in which a current command value hasreached a current limit value during fast feed.
 3. A method ofautomatically correcting abnormalities in a servo control systemcomprising the step of: computing a positional loop gain from a currentdroop rate when a command concerning speed indicates a rated rotationalspeed of a motor and a current command value has reached a current limitvalue during fast feed; and controlling so that said command concerningspeed will not exceed the rated rotational speed of said motor.